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2006 DODGE Sprinter Chassis Manual

1. 79 COMPONENT 8 2 4 4 81 8 1 DLC mmm 81 88 c EE 82 9 0 10 0 TABLE OF CONTENTS Continued CONNECTOR PINOUTS 4 233 km eR E ec e RR x a e ado aria 83 BRAKE FLUID LEVEL rs bete S dg RR e dun 83 BRAKE LAMP SWITCH C1 EXCEPT ESP isch ee ey RR Ren 83 BRAKE LAMP SWITCH C2 EXCEPT ESP BLACK RR RESERES 83 CONTROLLER ANTILOCK rie 0054055 RR RR 84 INSTRUMENT CLUSTER G2 WHITE s 894606565 CRM REEL 85 STEERING ANGLE SENSOR ke 5 Sess RE Yee ye Bes 85 TGS SWITCH ASR BLACK veod cien ue xdi DR et PRU ee se ERR a 85 WHEEL SPEED SENSOR LEFT FRONT ERREUR RR ka e m 85 WHEEL SPEED SENSOR LEFT BEAR ida der 86 WHEEL SPEED SENSOR RIGHT FRONT ka ERE n 86 WHEEL SPEED SENSOR RIGHT REAR 86 SCHEMATIC DIAGRAMS ss ssa RR RARE 87 10 1 BOSCH 5 7 ANTILOGK BRAKE SYSTEM sse eun 87 NOTES 1 0 INTRODUCTION The procedures contained this manual include all the specifications instructions and graphics needed to diagnose the Sprinter Chassis system problems Bosch 5 7 ABS ESP TCS ASR Braking System The diagnostics in this manual are based on the fai
2. GoTo 8 Turn the ignition off Disconnect the CAB harness connector Turn the ignition on Using a 12 volt test light connected to ground check the Fused Optional Equipment Relay Output circuit at the CAB harness connector NOTE The test light must illuminate brightly Compare the brightness to that of a direct connection to the battery Does the test light illuminate brightly Yes GoTo 9 No Repair the Fused Optional Equipment Relay Output circuit for an open Perform ABS VERIFICATION TEST VER 1 26 BRAKES CAN COMMUNICATION ERROR Continued ACTION APPLICABILITY Turn the ignition off All Disconnect the CAB harness connector Using a 12 volt test light connected to ground check both Fused circuits at the CAB harness connector NOTE The test light must illuminate brightly Compare the brightness to that of a direct connection to the battery Does the test light illuminate brightly Yes GoTo 10 No Repair the Fused B circuit for an open Perform ABS VERIFICATION TEST VER 1 Turn the ignition off Disconnect the CAB harness connector Using a 12 volt test light connected to 12 volts check the CAB harness connector Ground circuits NOTE The test light must illuminate brightly Compare the brightness to that of a direct connection to the battery Does the test light illuminate brightly Yes Replace the Controller Antilock Brake in accordance with t
3. circuits at the CAB harness connector NOTE The test light must illuminate brightly Compare the brightness to that of a direct connection to the battery Does the test light illuminate brightly Yes GoTo 7 No Repair the Fused B circuit for an open Perform ABS VERIFICATION TEST VER 1 Turn the ignition off Disconnect the CAB harness connector Turn the ignition on Using a 12 volt test light connected to ground check the F used Optional Equipment Relay Output circuit at the CAB harness connector 58 BRAKES PUMP MOTOR Continued ACTION APPLICABILITY Turn the ignition off All Disconnect the CAB harness connector Using a 12 volt test light connected to 12 volts check the CAB harness connector Ground circuits NOTE The test light must illuminate brightly Compare the brightness to that of a direct connection to the battery Does the test light illuminate brightly Yes Replace the Pump Motor in accordance with the Service Informa tion Perform ABS VERIFICATION TEST VER 1 Repair the Ground circuit for an open Perform ABS VERIFICATION TEST VER 1 59 BRAKES Symptom RELAY OUTPUT VOLTAGE E When Monitored and Set Condition RELAY OUTPUT VOLTAGE When Monitored Ignition On Continuously Set Condition When the supply voltage is under 9 4 under 8 8 during an ABS event or over 17 4 with vehicle speeds above
4. DIAGNOSTIC INFORMATION AND PROCEDURES BRAKES Symptom List ANTI LOCK BRAKE MODULE INTERNAL CAB INTERNAL Test Note All symptoms listed above are diagnosed using the same tests The title for the tests will be ANTI LOCK BRAKE MODULE INTERNAL When Monitored and Set Condition ANTI LOCK BRAKE MODULE INTERNAL When Monitored Ignition On Continuously Set Condition When there is a deviation from the expected result of a CAB internal self check CAB INTERNAL When Monitored Ignition On Continuously Set Condition When there is a deviation from the expected result of a CAB internal self check POSSIBLE CAUSES INTERMITTENT CAB INTERNAL DTC DAMAGED CAB CAB HARNESS CONNECTOR FUSED OPTIONAL EQUIPMENT RELAY OUTPUT CIRCUIT OPEN FUSED B CIRCUIT OPEN GROUND CIRCUIT OPEN ANTI LOCK BRAKE CONTROLLER ACTION APPLICABILITY Turn the ignition on With the DRBIII read DTCs With the DRBIII9 erase DTCs Turn the ignition off Turn the ignition on With the DRBIII9 read DTCs Does this DTC reset Yes GoTo 2 GoTo 6 BRAKES ANTI LOCK BRAKE MODULE INTERNAL Continued APPLICABILITY Turn the ignition off Disconnect the CAB harness connector Inspect the CAB 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 GoTo 3
5. Yes GoTo 6 No Repair as necessary Perform ABS VERIFICATION TEST VER 1 GoTo 13 33 BRAKES INCORRECT TONE WHEEL Continued APPLICABILITY Turn the ignition off All Disconnect the CAB harness connector Turn the ignition on Measure the voltage of both affected Wheel Speed Sensor circuits in the CAB harness connector 15 there any voltage present Yes Repair the affected Wheel Speed Sensor circuit for a short to voltage Perform ABS VERIFICATION TEST VER 1 GoTo 9 Turn the ignition off Disconnect the CAB harness connector Measure the resistance between ground and both affected Wheel Speed Sensor circuits in the CAB harness connector 15 the resistance below 5 0 ohms Yes Repair the affected Wheel Speed Sensor circuit for a short to ground Perform ABS VERIFICATION TEST VER 1 GoTo 10 Turn the ignition off Disconnect the CAB harness connector Measurethe resistance between the affected Wheel Speed Sensor circuits in the CAB harness connector 15 the resistance over 1 800 ohms Yes Repair the affected Wheel Speed Sensor circuit for an open Perform ABS VERIFICATION TEST VER 1 No GoTo 1 Turn the ignition off Disconnect the CAB harness connector Measure the resistance between the affected Wheel Speed Sensor circuits in the CAB harness connector Is the resistance under 1 100 ohms Yes Repair the affected Wheel Speed
6. 25 BRAKES CAN COMMUNICATION ERROR Continued ACTION APPLICABILITY Turn the ignition off All Disconnect the CAB harness connector Turn the ignition on Measure the voltage of the circuit Measure the voltage of the circuit Is the voltage above 3 0 volts for either circuit Yes Repair the CAN circuit s for a short to voltage Perform ABS VERIFICATION TEST VER 1 GoTo 5 Turn the ignition off Disconnect the CAB harness connector Measure the resistance between ground and the CAN circuit Measure the resistance between ground and the circuit Is the resistance below 5 0 ohms for either circuit Yes Repair the CAN circuit s for a short to ground Perform ABS VERIFICATION TEST VER 1 No GoTo 6 Turn the ignition off Disconnect the CAB harness connector Measure the resistance between the circuit and the circuit 15 the resistance below 5 0 ohms between the circuits Yes Repair the shorted CAN Perform ABS VERIFICATION TEST VER 1 GoTo 7 Turn the ignition off Disconnect the Engine Control Module harness connector Disconnect the CAB harness connector Measure the resistance of the CAN circuit Measure the resistance of the CAN circuit 15 the resistance above 5 0 ohms for either circuit Yes Repair the CAN circuit s for an open Perform ABS VERIFICATION TEST VER 1
7. circuits at the CAB harness connector BRAKES ANTI LOCK BRAKE MODULE INTERNAL Continued APPLICABILITY Turn the ignition off All Visually inspect the related wiring harness Look for any chafed pierced pinched or partially broken wires 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 Symptom BRAKE FLUID LEVEL POSSIBLE CAUSES INTERMITTENT DTC BRAKE FLUID LEVEL SWITCH SIGNAL CIRCUIT SHORT TO GROUND BRAKE FLUID LEVEL SWITCH ANTI LOCK BRAKE MODULE ACTION APPLICABILITY NOTE Before proceeding verify that the brake fluid is at the proper level All in accordance with the Service Information 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 read DTCs Does the DRBIII9 display BRAKE FLUID LEVEL Yes GoTo 2 GoTo 4 NOTE The brake fluid must be at the proper level Verify that the brake fluid is at the proper level in accordance with the Service Information Turn the ignition off Disconnect the Brake Fluid Level Switch harness connector Measure the resistance between the terminals of the Brake Fluid Level Switch 15 the resistance below 5 0 ohms Yes Replace the Brake Fluid Level Switch in accordance with the Servic
8. LEFT REAR OUTLET SOLENOID RIGHT FRONT INLET SOLENOID RIGHT FRONT OUTLET SOLENOID RIGHT FRONT LEFT REAR INLET SOLENOID RIGHT FRONT LEFT REAR OUTLET SOLENOID RIGHT REAR INLET SOLENOID RIGHT REAR OUTLET SOLENOID Test Note All symptoms listed above are diagnosed using the same tests The title for the tests will be LEFT FRONT INLET SOLE NOID When Monitored and Set Condition LEFT FRONT INLET SOLENOID When Monitored Ignition On Continuousy Set Condition When the electrical feedback signal does not match the actuation signal for the solenoid OR during the solenoid and pump motor test when all solenoids are tested in series and a solenoid response signal is detected POSSIBLE CAUSES INTERMITTENT SOLENOID DTC DAMAGED CAB CAB HARNESS CONNECTOR FUSED OPTIONAL EQUIPMENT RELAY OUTPUT CIRCUIT OPEN FUSED B CIRCUIT OPEN GROUND CIRCUIT OPEN ANTI LOCK BRAKE CONTROLLER 40 BRAKES LEFT FRONT INLET SOLENOID Continued ACTION APPLICABILITY NOTE If a system undervoltage or overvoltage DTC is set along with this DTC diagnose the system voltage DTC first Turn the ignition on With the DRBIII read DTCs With the DRBIII erase DTCs Turn the ignition off Turn the ignition on Start the engine Drive the vehicle over 15 km h 10 mph to test solenoid and pump circuits Stop the vehicle With the DRBIII read DTCs Does the DRBIII9 display any SOLENOID DTCs Yes GoTo 2 No GoT
9. Perform ABS VERIFICATION TEST VER 1 No GoTo 7 Turn the ignition off Inspect the affected Wheel Speed Sensor air NOTE Refer to the appropriate Service information if necessary for procedures or specifications 15 the affected air OK Yes GoTo 5 No Repair as necessary Perform ABS VERIFICATION TEST VER 1 47 5 LEFT FRONT WHEEL SPEED SENSOR SIGNAL Continued ACTION APPLICABILITY Turn the ignition off All Disconnect the Anti Lock Brake module harness connector Connect a voltmeter to the Wheel Speed Sensor and circuits at the Antilock Brake module harness connector Rotate the wheel at a speed of at least one revolution per second while monitoring the voltage 15 the AC voltage fluctuating above 120 mV Yes Replace the Controller Antilock Brake in accordance with the Service Information Perform ABS VERIFICATION TEST VER 1 Replace the affected Wheel Speed Sensor in accordance with the Service nformation 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 Look for broken bent pushed out or corroded terminals Look for any wiring conditions that may cause electromagnetic interference with the Wheel Speed Sensor circuits Inspect Wheel Speed sensors Tone Wheels Brake Rotors Wheel Bearings etc for conditio
10. With the DRBIII9 read DTCs Record DTC information NOTE If any other DTC is set along with this DTC diagnose the other DTC s first NOTE Electromagnetic radio interference can cause an intermittent system malfunction by interrupting communication between the sensor and the CAB With the DRBIII erase DTCs With the DRBIII perform the road test procedure in accordance with the Service Information With the DRBIII9 read DTCs NOTE Failure to perform the road test procedure properly can cause this DTC to set NOTE This DTC can only be cleared by a fault free road test Does this DTC reset Yes GoTo 2 GoTo 7 NOTE When the vehicle is in a turn the ESP compares the Steering Angle Sensor value and the speed of the inner and outer wheels to determine if the values are plausible Inspect the front end and steering components for damage or misalignment Inspect the Lateral Acceleration Sensor for correct mounting and installation Inspect the tires and wheels to make sure that they correct size All tires must be the same size Were any problems found Yes Repair or replace components as necessary in accordance with the Service Information No GoTo 3 29 BRAKES DRIVE TEST ERROR Continued APPLICABILITY Turn the ignition off All Disconnect the Lateral Acceleration Sensor harness connector Disconnect the CAB harness connector Turn the igniti
11. the Electronic Stabil ity Program ESP and the Traction Control System TCS found on the Sprinter 1 2 SIX STEP TROUBLESHOOTING PROCEDURE Diagnosis of the Antilock Brake Systems 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 INDENTIFICATION OF SYSTEM The Bosch 5 7 system can be identified by the 42 way Controller Antilock Brake CAB Hydraulic Control Unit HCU and Pump Motor being an integral electronic hydraulic unit mounted below the Master Cylinder with four Wheel Speed Sen sors one at each wheel Vehicles with the Traction Control System TCS ASR can be identified by the presence of the Traction Control System Switch TCCS located on the center instrument panel Vehicles with Electronic Stability Program ESP can be identified by the presence of the Steering Angle Sensor and the Lateral Acceleration Yaw Sensor 3 0 SYSTEM DESCRIPTION AND FUNCTIONAL OPERATION 3 1 ESP ESP system consists of the electronic control hydraulic unit steering angle sensor lateral acceleration yaw sensor and wheel speed sensors When the vehide is in a turn the ESP looks at the steering wheel angle sensor value and monitors the wheel speed of the inner and outer wheels to ensure the values are plausible The steering angle
12. 6 kph 4 mph POSSIBLE CAUSES INTERMITTENT RELAY OUTPUT VOLTAGE DTC BATTERY CHARGING SYSTEM FAILURE DAMAGED CAB CAB HARNESS CONNECTOR FUSED OPTIONAL EQUIPMENT RELAY OUTPUT CIRCUIT OPEN FUSED B 4 CIRCUIT OPEN GROUND CIRCUIT OPEN ANTI LOCK BRAKE CONTROLLER ACTION APPLICABILITY Turn the ignition on All With the DRBIII9 read DTCs With the DRBIII erase DTCs Turn the ignition off Turn the ignition on Start the engine Drive the vehicle above 6 km h 4 mph for at least 30 seconds Stop the vehicle With the DRBIII9 read DTCs Does the DRBIII9 display RELAY OUTPUT VOLTAGE Yes GoTo 2 No GoTo 8 Turn the ignition off Perform a battery and charging system test in accordance with the Service nforma tion NOTE Refer to symptom list for any problems related to the battery or charging system Were any problems found Yes Repair any charging system or battery related symptom s in accordance with the Service Information Perform ABS VERIFICATION TEST VER 1 GoTo 3 60 BRAKES RELAY OUTPUT VOLTAGE Continued APPLICABILITY Turn the ignition off All Disconnect the CAB harness connector Inspect the CAB 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 GoTo 4 Turn the ignition off Turn the ignition on With the DRBIII9
13. BRAKE SYSTEM ABS FUSE RELAY BLOCK FUSE 6 FUSE 9 FUSE 7 7 40A 25A BK RD Fused Optional UU 2 D Equipment Relay Output RD BK BRAKE SWITCH WT Fused Ignition Brake Switch Switch Output Output Outpu utpu BRAKE LAMP BK BL WT SWITCH BK RD Fused Ignition Brake Lamp Switch Output ai ea Switch Output C2 1 BL BK TO K ABS DLC CONTROLLER BK BL DG TCS SWITCH BK BL ANTILOCK 0 Relay TCS BRAKE Output Switch Sense Pe ory WT GY Sensor Signal BRAKE PRESSURE SENSOR BR Ground BK LF WSS LF BK wss LF WSS WT LR WSS LR BK wss LR WSS 87 SCHEMATIC DIAGRAMS BK DG Sensor Signa WT YL Sensor Signa TL RD Sensor Signa LATERAL ACCELERATION DG YL YAW RATE Sensor Signa SENSOR RD BL Sensor Supply BR Ground DG AWT To CAN C Bus 4 CAN Bus DG To CAN C Bus CAN Bus BK RD Fused Optional STEERING Equipment ANGLE Relay Output SENSOR BR g Ground BK RF WSS BR RF WSS YL RR WSS BR RR WSS 5 H E M G R 5 81342013 NOTES 88 DIAGNOSTIC TEST PROCEDURES TELL US DaimlerChrysler Corporation is constantly working to provide the technician the best diagnostic manuals possible Your comments and recommendations regarding the diagnostic manuals and procedures are appreciated To best understand
14. IMPLAUSIBLE CAN SIGNAL Continued ACTION APPLICABILITY Turn the ignition off All Disconnect the Steering Angle Sensor harness connector Inspect the harness and connectors related to this circuit If any problems are found repair as necessary If no problems are found replace the Steering Angle Sensor in accordance with the Service Information Turn the ignition on With the DRBIII clear DTCs Using the DRBIII9 perform the road test procedure With the DRBIII9 read DTCs Does this DTC reset Yes Replace the CAB in accordance with the Service I nformation No Test Complete The condition that set this DTC is not present at this time Monitor the DRBIII9 while wiggle testing the related harness and connectors Look for any related parameters to change or for the DTC to reset Inspect the related harness and connectors Look for any chafed pierced pinched or partially broken wires Look for broken bent pushed out or corroded terminals Were any problems found Yes Repair as necessary No Test Complete 69 5 Symptom STEERING ANGLE SENSOR IMPLAUSIBLE VALUE POSSIBLE CAUSES STEERING ANGLE SENSOR INTERMITTENT DTC STEERING COMPONENT INSPECTION STEERING ANGLE SENSOR ACTION APPLICABILITY NOTE If a system undervoltage or overvoltage DTC is set along with this All DTC diagnose the system voltage DTC first NOTE Electromagnetic radio interference can cause
15. IMPLAUSIBLE VALUE Continued ACTION APPLICABILITY The condition that set this DTC is not present at this time All Monitor the DRBIII9 while wiggle testing the related harness and connectors Look for any related parameters to change or for the DTC to reset Inspect the related harness and connectors Look for any chafed pierced pinched or partially broken wires Look for broken bent pushed out or corroded terminals Inspect the tires and wheels to make sure that they correct size All tires must be the same size Inspect the steering column and Steering Angle Sensor for correct mounting and installation Inspect the front end and steering components for damage or misalignment Were any problems found Yes Repair as necessary No Test Complete 71 5 Symptom STEERING ANGLE SENSOR IMPLAUSIBLE WHEEL SPEED POSSIBLE CAUSES STEERING ANGLE SENSOR INTERMITTENT DTC STEERING COMPONENT INSPECTION STEERING ANGLE SENSOR ACTION APPLICABILITY NOTE If a system undervoltage or overvoltage DTC is set along with this All DTC diagnose the system voltage DTC first NOTE Electromagnetic radio interference can cause an intermittent system malfunction by interrupting communication between the sensor and the CAB NOTE The Steering Angle Sensor is very sensitive to changes due to alignment problems The sensor must be recalculated using the DRBIII if aligament has been changed
16. INDICATOR SIGNAL 15 2081 GENERATOR FIELD DRIVER 16 20YL AIRBAG WARNING INDICATOR DRIVER 17 18 20BL VT D RELAY NO 1 CONTROL 18 20BL VT D RELAY NO 1 CONTROL STEERING ANGLE SENSOR CAV CIRCUIT FUNCTION 1 20DG WT CAN C BUS 2 2006 CAN C BUS 4 5 20BK RD FUSED OPTIONAL EQUIPMENT RELAY OUTPUT 6 20BR GROUND TCS SWITCH ASR BLACK CAV CIRCUIT FUNCTION 1 16GY DG RD LAMP DRIVER 2 18BK BL TCS SWITCH ASR SENSE 4 5 6 16BK BL DG FUSED IGNITION SWITCH OUTPUT 8 9 10 1688 GROUND WHEEL SPEED SENSOR LEFT FRONT CAV CIRCUIT FUNCTION 1 18BK LEFT FRONT WHEEL SPEED SENSOR 2 1888 LEFT FRONT WHEEL SPEED SENSOR 85 E R 4 2 5 R 4 CONNECTOR PINOUTS CONNECTOR NOT AVAILABLE CONNECTOR NOT AVAILABLE CONNECTOR NOT AVAILABLE WHEEL SPEED SENSOR LEFT REAR CAV CIRCUIT FUNCTION 1 18WT LEFT REAR WHEEL SPEED SENSOR 2 18BR LEFT REAR WHEEL SPEED SENSOR WHEEL SPEED SENSOR RIGHT FRONT CAV CIRCUIT FUNCTION 1 18BK RIGHT FRONT WHEEL SPEED SENSOR 2 18BR RIGHT FRONT WHEEL SPEED SENSOR WHEEL SPEED SENSOR RIGHT REAR CAV CIRCUIT FUNCTION 1 18BK RIGHT REAR WHEEL SPEED SENSOR 2 18BR RIGHT REAR WHEEL SPEED SENSOR 86 10 0 SCHEMATIC DIAGRAMS 10 1 BOSCH 5 7 ANTILOCK
17. Repair the Fused Optional Equipment Relay Output circuit for an open Perform ABS VERIFICATION TEST VER 1 Turn the ignition off Disconnect the CAB harness connector Using 12 volt test light connected to ground check both used B circuits at the CAB harness connector NOTE The test light must illuminate brightly Compare the brightness to that of a direct connection to the battery Does the test light illuminate brightly Yes GoTo 5 No Repair the Fused B circuit for an open Perform ABS VERIFICATION TEST VER 1 Turn the ignition off Disconnect the CAB harness connector Using a 12 volt test light connected to 12 volts check the CAB harness connector Ground circuits NOTE The test light must illuminate brightly Compare the brightness to that of a direct connection to the battery Does the test light illuminate brightly Yes Replace the Controller Antilock Brake in accordance with the Service Information Perform ABS VERIFICATION TEST VER 1 No Repair the 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 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 24 BRAKES Symptom CAN COMMUNICATI
18. Turn the ignition off Disconnect the CAB harness connector Turn the ignition on Using a 12 volt test light connected to ground check the Fused Optional Equipment Relay Output circuit at the CAB harness connector NOTE The test light must illuminate brightly Compare the brightness to that of a direct connection to the battery Does the test light illuminate brightly Yes GoTo 4 No Repair the Fused Optional Equipment Relay Output circuit for an open Perform ABS VERIFICATION TEST VER 1 NOTE The test light must illuminate brightly Compare the brightness to that of a direct connection to the battery Does the test light illuminate brightly Yes GoTo 5 No Repair the Fused B circuit for an open Perform ABS VERIFICATION TEST VER 1 Turn the ignition off Disconnect the CAB harness connector Using a 12 volt test light connected to 12 volts check the CAB harness connector Ground circuits NOTE The test light must illuminate brightly Compare the brightness to that of a direct connection to the battery Does the test light illuminate brightly Yes Replace the Controller Antilock Brake in accordance with the Service I nformation Perform ABS VERIFICATION TEST VER 1 No Repair the Ground circuit for an open Perform ABS VERIFICATION TEST VER 1 Turn the ignition off Disconnect the CAB harness connector Using a 12 test light connected to ground check both Fused
19. WARNING EXCEEDING THE LIMITS OF THE DRBIIIe MULTIMETER IS DANGEROUS CAN EXPOSE YOU TO SERIOUS OR POSSIBLE FATAL INJURY CAREFULLY READ AND UNDERSTAND THE CAUTIONS AND THE SPECIFICATION LIMITS Follow the vehicle manufacturer s service speci fications at all times Do not use the DRBIII if it has been damaged Do not use the test leads if the insulation 15 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 the measurement Do not try voltage or current mea surements that may exceed the rated capacity e Dono 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 megaohms Frequency Measured 0 10 kHz 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 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 readin
20. an intermittent system malfunction by interrupting communication between the sensor and the CAB NOTE The Steering Angle Sensor is very sensitive to changes due to alignment problems The sensor must be recalculated using the DRBIII if alignment has been changed by more than 5 degrees Turn the ignition on With the DRBIII erase DTCs With the DRBIII recalculate the Steering Angle Sensor Move the Steering Wheel from stop to stop several times With the DRBIII perform the road test procedure With the DRBIII9 read DTCs Does this DTC reset Yes GoTo 2 GoTo 3 NOTE When the vehicle is in a turn the ESP compares the Steering Angle Sensor value and the speed of the inner and outer wheels to determine if the values are plausible Inspect the front end and steering components for damage or misalignment Inspect the steering column and Steering Angle Sensor for correct mounting and installation Inspect the tires and wheels to make sure that they correct size All tires must be the same size Were any problems found Yes Repair or replace components as necessary in accordance with the Service Information No Inspec the Steering Angle Sensor for proper installation Inspect the wiring and connectors Repair as necessary If no other problems are found replace the Steering Angle Sensor in accor dance with the Service Information 70 5 STEERING ANGLE SENSOR
21. brakes are applied with the vehicle stationary Then the vehicle is driven at approxi mately 6 MPH The driver has to make left and right turns with a minimum 90 degree steering turning angle If the indicator lamp goes out every thing is in order If the lamp remains illuminated the DRBIII9 will display the fault codes that are causing the test to fail The road test function is set in the ESP control module and can only be deacti vated once there are no more fault codes detected The Steering Angle Sensor must be initialized procedure is carried out using the DRBIII9 to ensure that the module detects the exact position of the sensor The sensor must be calibrated any time wheel alignment is changed the steering column is removed and re installed or the sensor is replaced 3 8 USING THE DRBIII Refer to the DRBIII9 user s guide for instructions and assistance with reading diagnostic trouble codes erasing diagnostic trouble codes and other DRBIII9 functions 3 9 ERROR MESSAGES Under normal operation the DRBIII9 will dis play one of only two error messages User Requested WARM or User Requested COLD Boot If the DRBIII9 should display any other error message record the entire display and call the STAR Center for information and assistance This is a sample of such an error message display 2 14 date 26 J 193 file key_iff cc date ul 26 1993 line 548 err Ox1 Use
22. on and using the DRBIII read DTCs from ALL modules Are any DTC s present or is the original condition still present Yes Repair is not complete refer to the appropriate symptom No Repair is complete 80 APPLICABILITY All 5 o 8 0 COMPONENT LOCATIONS 8 1 DLC INDICATORS d TCS ASR E WARNING N INDICATOR T L 5 5 WARNING INDICATOR TCS ASR EVENT INDICATOR DLC FRONT WSS 810f9c57 81 5 UEM 8 2 CAB WSS M LUN E HYDRAULIC N CONTROL UNIT MOTOR HCU gt L 5 CONTROLLER ANTILOCK BRAKE CAB REAR WHEEL SPEED SENSOR 25 FRONT WHEEL SPEED SENSOR 810f9c60 CONNECTOR PINOUTS 9 0 CONNECTOR PINOUTS BRAKE FLUID LEVEL SWITCH CAV CIRCUIT FUNCTION BRAKE 1 20BR YL BRAKE FLUID LEVEL INDICATOR SIGNAL FLUID 2 16BR GROUND LEVEL SWITCH BRAKE LAMP SWITCH C1 EXCEPT ESP FUNCTION BRAKE SWITCH OUTPUT FUSED IGNITION SWITCH OUTPUT RUN START BRAKE LAMP SWITCH CAV CIRCUIT 1 1 20WT 2
23. outer wheels to determine if the values are plausible Inspect the front end and steering components for damage or misalignment Inspect the steering column and Steering Angle Sensor for correct mounting and installation Inspect the tires and wheels to make sure that they are correct size All tires must be the same size Were any problems found Yes Repair or replace components as necessary in accordance with the Service Information No Replacethe Steering Angle Sensor in accordance with the Service Information 66 BRAKES STEERING ANGLE SENSOR GREATER THAN 720 DEGREES Continued ACTION APPLICABILITY The condition that set this DTC is not present at this time All Monitor the DRBIII9 while wiggle testing the related harness and connectors Look for any related parameters to change or for the DTC to reset Inspect the related harness and connectors Look for any chafed pierced pinched or partially broken wires Look for broken bent pushed out or corroded terminals Inspect the tires and wheels to make sure that they correct size All tires must be the same size Inspect the steering column and Steering Angle Sensor for correct mounting and installation Inspect the front end and steering components for damage or misalignment Were any problems found Yes Repair as necessary No Test Complete 67 5 Symptom STEERING ANGLE SENSOR I
24. sensor also measures the speed at which the steering wheel is turned The ESP control module is very similar to the ABS ASR module The ESP is comprised of several other systems namely the HBA ABS TCS ASR EBD and FZR systems 3 2 ABS The Controller Antilock Brake CAB is used to monitor wheel speeds and modulates controls hy draulic pressure in each brake channel The modu lated hydraulic pressure is used to prevent wheel lock up during braking and maintain vehide stabil ity The CAB also provides a vehide speed signal VSS to the Electronic Control Module ECM During a non ABS stop the system functions as a standard braking system The CAB uses special sortware that monitors the wheel speed s and when certain criteria are met the software will GENERAL INFORMATION enable the HCU to perform the brake fluid manage ment control as the combination proportioning valves The Bosch 5 7 system uses the CAB HCU Pump Motor to make an integral electronic hydraulic unit which shares data with other electronic modules on the vehicle via the CAN C Bus network To access DTCs from the CAB the DRBIII9 uses the K ABS line located in the Data Link Connector DLC 3 3 BRAKE ASSIST SYSTEM HBA The Brake Assist System HBA analyzes how hard and fast the driver wants to brake It monitors the brake pressure via a pressure sensor The passenger car brake assist system uses a vacuum booster solenoid The Sprinter uses the hydr
25. the ABM ACM ATC CTM ECM IC SKREEM SLA or SSM was replaced 4 If the SKREEM was replaced program all RKE transmitters used with this vehicle 5 NOTE Perform the next 8 steps of this procedure if either diagnosing the Automatic Temperature Control ATC system or if repairs were made to the ATC system of the following criteria must be met in order to successfully run the Function Test 6 With DRBIII9 record and erase ATC DTCs 7 Placethe shift lever in Park 8 Start the engine Allow the engine to reach normal operating temperature 9 Set the blower to high speed 10 Press the Air Conditioning switch On 11 With the DRBIIIS verify that the ambient temperature 15 above 59 F 15 C the refrigerant pressure is between 29 and 348 PSI 2 and 24 bar the evaporator temperature is above 36 5 F 2 5 C and the coolant temperature is above 158 F 70 C 12 With the DRBIII in select System Tests and select ATC Function Test When theATC Function Test is complete proceed to the next step of this procedure 13 With the DRBIII read active ATC DTCs If any DTC is active or if the original condition is still present proceed to the conclusion question and answer Yes 14 With the DRBIIIS record and erase all DTCs from ALL modules Start and run the engine for 2 minutes Operate all functions of the system that caused the original concern 15 Turn the ignition off and wait 5 seconds Turn the ignition
26. to change or for the DTC to reset Inspect the related harness and connectors Look for any chafed pierced pinched or partially broken wires Look for broken bent pushed out or corroded terminals Were any problems found Yes Repair as necessary No Test Complete 73 5 Symptom STEERING ANGLE SENSOR INTERNAL FAULT POSSIBLE CAUSES STEERING ANGLE SENSOR INTERMITTENT DTC STEERING ANGLE SENSOR ACTION APPLICABILITY NOTE If a system undervoltage or overvoltage DTC is set along with this All DTC diagnose the system voltage DTC first NOTE Electromagnetic radio interference can cause an intermittent system malfunction by interrupting communication between the sensor and the CAB Turn the ignition on With the DRBIII erase DTCs Move the Steering Wheel from stop to stop several times With the DRBIII9 perform the road test procedure With the DRBIIIS read DTCs NOTE The Steering Angle Sensor is very sensitive to changes due to alignment problems The sensor must be recalculated using the DRBIII if alignment has been changed by more than 5 degrees Does this DTC reset Yes Inspect the Steering Angle Sensor for proper installation Inspect the wiring and connectors Repair as necessary If no other problems are found replace the Steering Angle Sensor in accor dance with the Service I nformation No GoTo 2 The condition that set this DTC is not present at this t
27. your suggestion please complete the form giving us as much detail as possible Model ________________ ________ ____________ Engine Transmission Diagnostic Procedure Comments recommendations if necessary draw sketch Name Submitted by Address City State Zip Business Phone All comments become property of DaimlerChrysler Corporation and may be used without compensation FOLD HERE NO POSTAGE NECESSARY IF MAILED BUSINESS REPLY MAIL IN THe FIRST CLASS MAIL PERMIT NO 124 CENTER LINE STATES POSTAGE WILL BE PAID BY ADDRESSEE DaimlerChrysler Corporation Dealer Technical Operations 800 Chrysler Drive CIMS 486 02 76 Auburn Hills 48326 2757 FOLD HERE
28. 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 INDENTIFICATION OF 5 5 1 SYSTEM DESCRIPTION AND FUNCTIONAL 1 1 1 3 3 BRAKE ASSIST SYSTEM 2 3 4 TCS c 2 3 5 ELECTRONIC BRAKE DISTRIBUTION 2 3 6 VEHICLE CONTROLLING 2 2 37 SYSTEM 8 2 371 AND TCS ASR INDICATORS 3 3 7 2 CONTROLLER ANTILOCK BRAKE 3 373 HYDRAULIC CONTROL UNIT 3 3 7 4 5 5 5 5 8 3 3 7 5 5 5 6 4 38 USING THE 4 3 9 DRBIII ERROR MESSAGES 4 3 9 1 DRBIII DOES NOT POWER UP BLANK 5 5 3 9 2 DISPLAY IS 5 DISCLAIMERS SAFETY
29. 16RD BK 3 20BK BL RD BRAKE LAMP SWITCH C1 EXCEPT ESP BLACK FUNCTION 3 1 BRAKE LAMP SWITCH C2 EXCEPT ESP BLACK CAV CIRCUIT 1 FUSED IGNITION SWITCH OUTPUT RUN START BRAKE LAMP SWITCH OUTPUT 16BK BL WT BRAKE 2 16BK RD LAMP 3 SWITCH C2 EXCEPT ESP 83 o E R 4 2 7 R 4 7 CONNECTOR PINOUTS 0 be Se ci t 26 pe pape nem high nd 42 CONTROLLER ANTILOCK BRAKE CONTROLLER ANTILOCK BRAKE CAV CIRCUIT FUNCTION 1 1288 GROUND 2 1280 FUSED 80 3 4 5 GROUND 6 1480 FUSED 80 7 8 20BK DG SENSOR SIGNAL 9 20YLIWT SENSOR SIGNAL 10 20YL RD SENSOR SIGNAL 11 18BL BK K ABS SHIFTER ASSEMBLY 12 188K LEFT FRONT WHEEL SPEED SENSOR 13 14 20wT LEFT REAR WHEEL SPEED SENSOR 15 RIGHT FRONT WHEEL SPEED SENSOR 16 18BK RIGHT FRONT WHEEL SPEED SENSOR 17 18 19 20 20WT BRAKE SWITCH OUTPUT 21 2088 GROUND EN 23 18BK RD FUSED OPTIONAL EQUIPMENT RELAY OUTPUT 24 200 CAN C BUS 25 20BR SENSOR GROU
30. 3 Turn the ignition off Disconnect the CAB harness connector Using a 12 volt test light connected to 12 volts check the CAB harness connector Ground circuits NOTE The test light must illuminate brightly Compare the brightness to that of a direct connection to the battery Does the test light illuminate brightly Yes Replace the Controller Antilock Brake in accordance with the Service Information Perform ABS VERIFICATION TEST VER 1 No Repair the Ground circuit for an open Perform ABS VERIFICATION TEST VER 1 75 BRAKES SYSTEM OVERVOLTAGE Continued ACTION APPLICABILITY Turn the ignition off All Visually inspect the related wiring harness Look for any chafed pierced pinched or partially broken wires 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 76 5 Symptom SYSTEM UNDERVOLTAGE POSSIBLE CAUSES INTERMITTENT DTC DAMAGED CAB CAB HARNESS CONNECTOR FUSED OPTIONAL EQUIPMENT RELAY OUTPUT CIRCUIT HIGH RESISTANCE FUSED B CIRCUIT HIGH RESISTANCE GROUND CIRCUIT HIGH RESISTANCE ANTI LOCK BRAKE CONTROLLER ACTION APPLICABILITY NOTE An undercharged battery may cause this DTC to set Repair any All Powertrain charging system DTCs before continuing Turn the ignition on With the DRBIII read DTCs With the DRBIII er
31. 5 5 41 6 2 22 22222222 5 SAFETY 5 421 TECHNICIAN SAFETY 5 4 22 VEHICLE PREPARATION FOR 5 42 3 SERVICING SUB ASSEMBLIES 5 4 24 DRBIII SAFETY 6 4 3 WARNING Qoa de aene oa Eee Ora 6 431 VEHICLE DAMAGE 86 6 4 3 2 ROAD TESTING A COMPLAINT 6 44 d ENDS 6 REQUIRED TOOLS AND EQUIPMENT 7 GLOSSARY OF 6 7 DIAGNOSTIC INFORMATION AND PROCEDURES 9 BRAKES CAB ANTI LOCK BRAKE MODULE INTERNAL 10 CAB INTERNA se Er oe rn E Dao e ol UR S mesg 10 BRAKE FLUID 13 BRAKE PRESSURE SENSOR 15 BRAKE SWITCH ees 17 CAB GHECK SUM 21 2 2 222222 2 2 4 4 23 COMMUNICATION ERROR 25 TABLE CONTENTS Continued DRIVE TEST COMPLETED SU
32. AL ACCELERATION SENSOR CIRCUIT OPEN LATERAL ACCELERATION SENSOR ANTI LOCK BRAKE CONTROLLER APPLICABILITY Turn the ignition off All Turn the ignition on With the DRBIII read DTCs Record DTC information NOTE If a system undervoltage or overvoltage DTC is set along with this DTC diagnose the system voltage DTC first NOTE Electromagnetic radio interference can cause an intermittent system malfunction by interrupting communication between the sensor and the CAB With the DRBIII erase DTCs Road test the vehicle and perform several braking maneuvers With the DRBIII perform the road test procedure With the DRBIII9 read DTCs Does this DTC reset Yes GoTo 2 No GoTo 7 NOTE When the vehicle is in a turn the ESP compares the Steering Angle Sensor value and the speed of the inner and outer wheels to determine if the values are plausible Inspect the front end and steering components for damage or misalignment Inspect the Lateral Acceleration Sensor for correct mounting and installation Inspect the tires and wheels to make sure that they correct size All tires must be the same size Were any problems found Yes Repair or replace components as necessary in accordance with the Service Information No GoTo 3 36 BRAKES LATERAL ACCELERATION SENSOR CIRCUIT Continued ACTION APPLICABILITY Turn the ignition off All Disconnect the Lateral Accele
33. AUSES LATERAL ACCELERATION SENSOR CIRCUIT INTERMITTENT DTC LATERAL ACCELERATION SENSOR ACTION APPLICABILITY Turn the ignition off All Turn the ignition on With the DRBIII read DTCs Record DTC information NOTE If a system undervoltage or overvoltage DTC is set along with this DTC diagnose the system voltage DTC first NOTE Electromagnetic radio interference can cause an intermittent system malfunction by interrupting communication between the sensor and the CAB With the DRBIII erase DTCs Road test the vehicle and perform several steering and braking maneuvers With the DRBIII perform the road test procedure With the DRBIII9 read DTCs Does this DTC reset Yes Replace the Lateral Acceleration Sensor in accordance with the Service I nformation No GoTo 2 The condition that set this DTC is not present at this time Monitor the DRBIII9 while wiggle testing the related harness and connectors Look for any related parameters to change or for the DTC to reset Inspect the related harness and connectors Look for any chafed pierced pinched or partially broken wires Look for broken bent pushed out or corroded terminals Were any problems found Yes Repair as necessary No Test Complete 39 BRAKES Symptom List LEFT FRONT INLET SOLENOID LEFT FRONT OUTLET SOLENOID LEFT FRONT RIGHT REAR INLET SOLENOID LEFT FRONT RIGHT REAR OUTLET SOLENOID LEFT REAR INLET SOLENOID
34. Angle All Sensor has not been Calibrated Turn the ignition on With the DRBIII clear DTCs With the DRBIII perform the Steering Angle Calibration under Miscellaneous functions Turn the ignition off Turn the ignition on Test drive the vehicle and perform the Road Test Function With the DRBIII read DTCs Does this DTC reset Yes Replacethe Steering Angle Sensor in accordance with the Service Information No Test Complete 65 5 Symptom STEERING ANGLE SENSOR GREATER THAN 720 DEGREES POSSIBLE CAUSES STEERING ANGLE SENSOR INTERMITTENT DTC STEERING COMPONENT INSPECTION STEERING ANGLE SENSOR ACTION APPLICABILITY NOTE If a system undervoltage or overvoltage DTC is set along with this All DTC diagnose the system voltage DTC first NOTE Electromagnetic radio interference can cause an intermittent system malfunction by interrupting communication between the sensor and the CAB NOTE The Steering Angle Sensor is very sensitive to changes due to alignment problems The sensor must be recalculated using the DRBIII if alignment has been changed by more than 5 degrees Turn the ignition on With the DRBIII erase DTCs Move the Steering Wheel from stop to stop several times With the DRBIII read DTCs Does this DTC reset Yes GoTo 2 GoTo 3 NOTE When the vehicle is in a turn the ESP compares the Steering Angle Sensor value and the speed of the inner and
35. CCESSFULLY etes seb OI hm RR RE ER 28 DRIVE TEST ERROR bss ones sess RE oe es ENG E 29 INCORRECT TONE WHEEL 5 32 LATERAL ACCELERATION SENSOR 36 LATERAL ACCELERATION SENSOR IMPLAUSIBLE 36 LATERAL ACCELERATION SENSOR INTERNAL FAULT 39 LEFT FRONT INLET SOLENOID 22 2 5 p an RECHERCHE ed 40 LEFT FRONT OUTLET SOLENOID 1 3 Rx ERA RR REDDERE RR ERR 40 LEFT FRONT RIGHT REAR INLET SOLENOID 5 58535 8 85988988 065654 40 LEFT FRONT RIGHT REAR OUTLET SOLENOID RR RR IRR 40 REAR INLET CRUCE be hu IER EF E RP EE YE 40 LEFT HEAR OUTLET SOLENOID 2r rng Er ERE CREE ER 40 RIGHI FRONT INLET SOLENOID Kater iti Ni NEDE 40 RIGHT FRONT OUTLET SOLENOID 40 RIGHT FRONT LEFT REAR INLET SOLENOID esd ee 40 RIGHT FRONT LEFT REAR OUTLET SOLENOID 40 RIGHT REAR INLET SOLENOID lt s 2se4 4500494094 vhs ERI 40 RIGHT REAR OUTLET SOLENOID 4 55 RR eves RE 40 LEFT FRONT WHEEL SPEED SENSOR CIRCUIT weed re Ir RR 43 LEFT REAR WHEEL SPEED SENSOR CIRCUIT 43 RIGHT FRONT WHEEL SPEED SENSOR CIRCUIT 15x he 43 RIGHT REAR WHEEL SPEED SENSOR CIRCUIT sce er RE RR 43 LEFT FRONT WH
36. EEL SPEED SENSOR SIGNAL hm icu i xen 46 LEFT REAR WHEEL SPEED SENSOR SIGNAL cese A 46 RIGHT FRONT WHEEL SPEED SENSOR SIGNAL RR RR Res 46 RIGHT REAR WHEEL SPEED SENSOR terre hera RE eher 46 WHEEL SPEED SENSOR SIGNAL he CE EA RA Gen a eda 46 NO COMMUNICATION WITH BUS RE Ra En EEG RR RC REX Res 49 NO 242525 5 m 52 NO COMMUNICATION WITH IC 2s uu 2S thats eed 54 PARAMETERIZATION ERROR m ray en han era 56 PUMP MOTOR kein ac 57 RELAY OUTPUT VOLTAGE corate aina dened but nee 60 SOLENOID RELAY 63 STEERING ANGLE SENSOR CALIBRATION ERROR 65 STEERING ANGLE SENSOR GREATER THAN 720 DEGREES 66 STEERING ANGLE SENSOR IMPLAUSIBLE CAN 6 68 STEERING ANGLE SENSOR IMPLAUSIBLE VALUE 70 STEERING ANGLE SENSOR IMPLAUSIBLE WHEEL SPEED 72 STEERING ANGLE SENSOR INTERNAL 2 2 74 55 aba orare Da ER 75 SYSTEM UNDERVOLTAGE ad dada PP E SEE ET RS ede Bates 77 VERIFICATION TESTS VERIFICATION TES Skera
37. MPLAUSIBLE CAN SIGNAL POSSIBLE CAUSES STEERING ANGLE SENSOR INTERMITTENT DTC STEERING ANGLE SENSOR CAN CIRCUIT OPEN STEERING ANGLE SENSOR ANTI LOCK BRAKE CONTROLLER ACTION APPLICABILITY NOTE If a system undervoltage or overvoltage DTC is set along with this All DTC diagnose the system voltage DTC first NOTE Electromagnetic radio interference can cause an intermittent system malfunction by interrupting communication between the sensor and the CAB NOTE The Steering Angle Sensor is very sensitive to changes due to alignment problems The sensor must be recalculated using the DRBIII if alignment has been changed by more than 5 degrees Turn the ignition on With the DRBIII erase DTCs Test drive the vehicle Using the DRBIII perform the road test procedure With the DRBIII9 read DTCs NOTE If the ESP lamp remains illuminated after the test has completed fault code will be set indicating the cause of the failure Does this DTC reset Yes GoTo 2 GoTo 4 Turn the ignition off Disconnect the Steering Angle Sensor harness connector Disconnect the CAB harness connector Measure the resistance of the Steering Angle Sensor circuit Measure the resistance of the Steering Angle Sensor CAN circuit Is the resistance above 5 0 ohms for either circuit Yes Repair the Steering Angle Sensor CAN circuit for an open No GoTo 3 68 5 STEERING ANGLE SENSOR
38. NAL LEFT REAR WHEEL SPEED SENSOR SIGNAL RIGHT FRONT WHEEL SPEED SENSOR SIGNAL RIGHT REAR WHEEL SPEED SENSOR SIGNAL WHEEL SPEED SENSOR SIGNAL ERROR SERIES Test Note All symptoms listed above are diagnosed using the same tests The title for the tests will be LEFT FRONT WHEEL SPEED SENSOR SIGNAL When Monitored and Set Condition LEFT FRONT WHEEL SPEED SENSOR SIGNAL When Monitored Ignition On Continuously Set Condition When the value of the wheel speed sensor signal is missing at vehicle speeds over 40 km h 25 mph OR during a start up test with vehicle speeds over 12km h 8 mph OR the vehicle is accelerated by 18 km h 12 mph after a wheel speed sensor signal has been lost POSSIBLE CAUSES INTERMITTENT WHEEL SPEED SENSOR SIGNAL DTC DAMAGED SENSOR CAB HARNESS CONNECTOR DAMAGED WHEEL SPEED SENSOR TONE WHEEL EXCESSIVE WHEEL SPEED SENSOR AIR GAP DAMAGED WHEEL BEARING DAMAGED BRAKE LININGS COMPONENTS WHEEL SPEED SENSOR FAILURE ANTI LOCK BRAKE CONTROLLER ACTION APPLICABILITY NOTE Refer to the symptom list and repair any WHEEL SPEED SENSOR All CIRCUIT DTCs before continuing Turn the ignition on With the DRBIII9 in Sensors monitor ALL the Wheel Speed Sensor signals while an assistant drives the vehicle Slowly accelerate from a stop to 65 km h 40 mph NOTE Wheel Speed should not vary by more than 10 from wheel to wheel when driving in a straight line Do any of the Wheel Speed Sensor signals var
39. ND 26 2 BRAKE PRESSURE SENSOR SIGNAL 18BK BL TCS SWITCH ASR SENSE 28 18BR LEFT FRONT WHEEL SPEED SENSOR 29 208 LEFT REAR WHEEL SPEED SENSOR 30 20BR RIGHT REAR WHEEL SPEED SENSOR 31 20 RIGHT REAR WHEEL SPEED SENSOR 32 18BK RD BRAKE LAMP SWITCH OUTPUT 33 34 35 36 37 38 39 20RD BL POWER INPUT 40 2006 CAN C BUS 41 200G YL SENSOR SIGNAL 42 20WT RD 5 VOLT SUPPLY 84 WHITE oa oa oa oa oa INSTRUMENT CLUSTER C2 STEERING ANGLE SENSOR BLACK TCS SWITCH ASR CONNECTOR NOT AVAILABLE CONNECTOR PINOUTS INSTRUMENT CLUSTER C2 WHITE CAV CIRCUIT FUNCTION 1 2 3 20RD YL FUSED B 4 20BR WT BRAKE WEAR SENSOR SIGNAL 5 6 18BR GROUND 20GY DG RD LAMP DRIVER 8 20BL WT FUSED HIGH BEAM SWITCH OUTPUT 9 20BL RD WT VEHICLE SPEED SENSOR OUTPUT 10 20BK FUSED IGNITION SWITCH OUTPUT RUN START 11 20BL BK KEY IN IGNITION SWITCH SIGNAL 12 13 20BK WT LEFT TURN SIGNAL 14 20BR YL BRAKE FLUID LEVEL
40. ON ERROR POSSIBLE CAUSES CAN DTCS PRESENT IN OTHER MODULES INTERMITTENT CAN COMMUNICATION ERROR DTC DAMAGED CAB CAB HARNESS CONNECTOR CAN CIRCUIT S SHORT TO VOLTAGE CAN CIRCUIT S SHORTED TOGETHER CAN CIRCUIT S SHORT TO GROUND CAN CIRCUIT S OPEN FUSED OPTIONAL EQUIPMENT RELAY OUTPUT CIRCUIT OPEN FUSED B CIRCUIT OPEN GROUND CIRCUIT OPEN ANTI LOCK BRAKE CONTROLLER ACTION APPLICABILITY Turn the ignition on All NOTE Diagnose any Steering Angle Sensor DTCs that are present in this module before continuing With the DRBIII read DTCs in the Engine Control Module Transmission Control Module and Instrument Cluster Are there any CAN communication DTCs present in any of these modules Yes Refer to the diagnostic procedures for any CAN DTCs in ECM TCM and Cluster before proceeding with this test Perform ABS VERIFICATION TEST VER 1 GoTo 2 NOTE If a system undervoltage or overvoltage DTC is set along with this DTC diagnose the system voltage DTC first Turn the ignition on With the DRBIII erase DTCs Turn the ignition off Start the engine With the DRBIII read DTCs Does this DTC reset Yes GoTo 3 No GoTo 11 Turn the ignition off Disconnect the CAB harness connector Inspect the CAB 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 GoTo 4
41. PEED SENSOR CIRCUIT OPEN WHEEL SPEED SENSOR CIRCUITS SHORTED TOGETHER ANTI LOCK BRAKE CONTROLLER APPLICABILITY NOTE If a system undervoltage or overvoltage DTC is set along with this All DTC diagnose the system voltage DTC first 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 read DTCs Does the DRBIII9 display any WHEEL SPEED SENSOR CIRCUIT DTCs Yes GoTo 2 GoTo 7 43 BRAKES LEFT FRONT WHEEL SPEED SENSOR CIRCUIT Continued APPLICABILITY Turn the ignition off All Disconnect the CAB harness connector Inspect the CAB 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 GoTo 3 Turn the ignition off Disconnect the CAB harness connector Turn the ignition on Measure the voltage of both affected Wheel Speed Sensor circuits in the CAB harness connector NOTE If the wheel is rotating voltage will be present 15 there any voltage present Yes Repair the affected Wheel Speed Sensor circuit for a short to voltage Perform ABS VERIFICATION TEST VER 1 GoTo 4 Turn the ignition off Disconnect the CAB harness connector Measure the resistance between ground and both affected Wheel Speed Sensor circuits in the CAB harne
42. Sensor circuits for a short to each other Perform ABS VERIFICATION TEST VER 1 GoTo 12 Turn the ignition off Disconnect the CAB harness connector Measure the resistance between the affected Wheel Speed Sensor circuits in the CAB harness connector Is the resistance between 1 100 and 1 800 ohms Yes GoTo 13 No Replace the Wheel Speed Sensor in accordance with the Service Information Perform ABS VERIFICATION TEST VER 1 34 BRAKES INCORRECT TONE WHEEL Continued APPLICABILITY The condition necessary to set this DTC is not present at this time 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 Were any problems found Yes Repair as necessary Perform ABS VERIFICATION TEST VER 1 No Test Complete 35 BRAKES Symptom List LATERAL ACCELERATION SENSOR CIRCUIT LATERAL ACCELERATION SENSOR IMPLAUSIBLE Test Note All symptoms listed above are diagnosed using the same tests The title for the tests will be LATERAL ACCELERATION SENSOR CIRCUIT POSSIBLE CAUSES LATERAL ACCELERATION SENSOR CIRCUIT INTERMITTENT DTC STEERING COMPONENT INSPECTION LATERAL ACCELERATION SENSOR CIRCUIT SHORT TO VOLTAGE LATERAL ACCELERATION SENSOR CIRCUIT SHORT TO GROUND LATER
43. 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 vehides the parking brake does not hold the front drive wheels When servicing a vehide always wear eye pro tection and remove any metal jewelry such as watchbands or bracelets that might make an inad vertent electrical contact When diagnosing an antilock brake or adjustable pedals system problem it is important to follow approved procedures where applicable These pro cedures can be found in the service manual F ollow ing these procedures is very important to safety of individuals performing diagnostic tests 4 2 2 VEHICLE PREPARATION FOR TESTING Make sure the vehide being tested has a fully charged battery If it does not false diagnostic codes or error messages may occur 4 2 3 SERVICING SUB ASSEMBLIES Some components of the antilock brake and trac tion control are intended to be serviced in assembly only Attempting to remove or repair certain sub components 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 GENERAL INFORMATION 4 2 4 SAFETY INFORMATION
44. Test Complete 22 BRAKES Symptom CAB OPTION When Monitored and Set Condition CAB OPTION When Monitored Ignition On Once Set Condition When the vehicle line information transmitted does not match the expected values POSSIBLE CAUSES INTERMITTENT CAB OPTION DTC DAMAGED CAB CAB HARNESS CONNECTOR FUSED OPTIONAL EQUIPMENT RELAY OUTPUT CIRCUIT OPEN FUSED B CIRCUIT OPEN GROUND CIRCUIT OPEN ANTI LOCK BRAKE CONTROLLER ACTION APPLICABILITY Turn the ignition on All With the DRBIII9 read DTCs With the DRBIII9 erase DTCs Turn the ignition off Turn the ignition on With the DRBIII9 read DTCs Does the DRBIII9 display CAB OPTION Yes GoTo 2 No GoTo 6 Turn the ignition off Disconnect the CAB harness connector Inspect the CAB 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 3 23 BRAKES CAB OPTION Continued ACTION APPLICABILITY Turn the ignition off Disconnect the CAB harness connector Turn the ignition on Using 12 volt test light connected to ground check the Fused Optional Equipment Relay Output circuit at the CAB harness connector NOTE The test light must illuminate brightly Compare the brightness to that of a direct connection to the battery Does the test light illuminate brightly Yes GoTo 4
45. UMP MOTOR Yes GoTo 4 No GoTo 2 Turn the ignition off Turn the ignition on With the DRBIII9 actuate the Pump Motor Is the Pump Motor running Yes GoTo 3 No GoTo 4 57 BRAKES PUMP MOTOR Continued ACTION APPLICABILITY The conditions necessary to set this DTC are not present at this time Monitor DRBIII9 parameters while wiggle testing the related wiring harness and connectors Turn the ignition off Visually inspect the related wiring harness and connectors Look for any chafed pierced pinched or partially broken wires 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 Turn the ignition off Disconnect the CAB harness connector Inspect the CAB 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 5 NOTE The test light must illuminate brightly Compare the brightness to that of a direct connection to the battery Does the test light illuminate brightly Yes GoTo 6 No RepairtheFused Optional Equipment Relay Output circuit for an open Perform ABS VERIFICATION TEST VER 1 Turn the ignition off Disconnect the CAB harness connector Using 12 volt test light connected to ground check both Fused
46. Using 12 volt test light connected to ground check both used B circuits at the CAB harness connector NOTE The test light must illuminate brightly Compare the brightness to that of a direct connection to the battery Does the test light illuminate brightly Yes GoTo 5 No Repair the Fused B circuit for an open Perform ABS VERIFICATION TEST VER 1 Turn the ignition off Disconnect the CAB harness connector Using a 12 volt test light connected to 12 volts check the CAB harness connector Ground circuits NOTE The test light must illuminate brightly Compare the brightness to that of a direct connection to the battery Does the test light illuminate brightly Yes Replace the Controller Antilock Brake in accordance with the Service Information Perform ABS VERIFICATION TEST VER 1 No Repair the 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 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 64 5 Symptom STEERING ANGLE SENSOR CALIBRATION ERROR POSSIBLE CAUSES STEERING ANGLE SENSOR CALIBRATION ERROR ACTION APPLICABILITY NOTE This is an informational DTC indicating that the Steering
47. ability The Pump Motor is attached to the HCU which works with the ABS and TCS and is controlled by the CAB The primary function is to provide extra amount of fluid when needed 3 7 4 SWITCHES SENSORS BRAKE SWITCH BS This switch prepares the CAB for a possible antilock event The CAB uses an output state voltage from the BS when the brake pedal is either released depressed used Igni tion Switch Output circuit supplies 12 volts to the BS A released brake pedal will close the BS circuit and the BS Output circuit supplies 12 volts to the CAB When the driver depresses the brake pedal the BS Output circuit voltage drops to 0 volts and the CAB senses the brake pedal state This tells the CAB what position the brake pedal is currently in to make an ABS event possible When using the DRBIII in Inputs Outputs the BS and BLS will GENERAL INFORMATION read opposite switch states Note The BS and BLS are in the same switch housing BRAKE LAMP SWITCH BLS This switch pre pares the CAB for a possible antilock event The CAB uses an output state voltage from the BLS when the brake pedal is either depressed released The Fused Ignition Switch Output circuit supplies 12 volts to the BLS A depressed brake pedal will close the BLS circuit and the BLS Output circuit supplies 12 volts at the CAB When the driver releases the brake pedal the BLS Output circuit voltage drops to 0 volts and the CAB senses the brake pedal state Thi
48. accordance with the Service Information Perform ABS VERIFICATION TEST VER 1 GoTo 6 Turn the ignition off All Disconnect the C1 Brake Switch harness connector BRAKES BRAKE SWITCH CIRCUIT Continued ACTION APPLICABILITY Turn the ignition off All Disconnect the appropriate brake switch harness connector Turn the ignition on Using a 12 volt test light connected to ground check the Fused Ignition Switch Output circuit at the harness connector NOTE The test light must illuminate brightly Compare the brightness to that of a direct connection to the battery Is the test light illuminated and bright Yes GoTo 7 No Repair the Fused Ignition Switch Output circuit for an open Perform ABS VERIFICATION TEST VER 1 Turn the ignition off Disconnect the CAB harness connector Disconnect the appropriate brake switch harness connector Turn the ignition on Measure the voltage of the output circuit at the brake switch harness connector NOTE Measurement is taken at the Brake Switch Output circuit or the Brake Lamp Output circuit as determined by the previously performed switch test 15 there any voltage present Yes Repair the affected circuit for a short to voltage Perform ABS VERIFICATION TEST VER 1 No GoTo 8 Turn the ignition off Disconnect the CAB harness connector Disconnect the appropriate brake switch harness connector Measure the resistance between ground and
49. active for one minute on one or more wheels OR interference on one or more wheels OR deviation of two wheel speeds at either side of vehicle by 6 km h 4 mph or at the front axle by 10 km h 7 mph If at least one wheel is 5 km h 3 mph or less a wheel speed deviation of adjoining wheels of 12 km h 8 mph is allowed POSSIBLE CAUSES INTERMITTENT INCORRECT TONE WHEEL DTC INCORRECT TIRES ON VEHICLE TIRE CIRCUMFERENCES NOT MATCHING WHEEL SPEED SENSOR CIRCUIT SHORT TO VOLTAGE INCORRECT TONE WHEEL WHEEL SPEED SENSOR CIRCUIT SHORT TO GROUND DAMAGED WHEEL BEARING WHEEL SPEED SENSOR CIRCUIT OPEN DAMAGED BRAKE LININGS COMPONENTS WHEEL SPEED SENSOR CIRCUITS SHORTED TOGETHER WHEEL SPEED SENSOR ACTION APPLICABILITY Turn the ignition on All With the DRBIII9 read DTCs With the DRBIII erase DTCs Turn the ignition off Turn the ignition on Road test the vehicle During the road test drive the vehicle above 100 km h 62 mph for at least 3 minutes and perform several stops and Antilock stops Stop the vehicle With the DRBIII9 read DTCs Does the DRBIII9 display INCORRECT TONE WHEEL Yes GoTo 2 No GoTo 13 32 BRAKES INCORRECT TONE WHEEL Continued ACTION APPLICABILITY Turn the ignition off Inspect the tire sizes on the vehicle Is a smaller than production tire or spare tire being used Yes Repair as necessary Perform ABS VERIFICATION TEST VER 1 GoTo 3 Turn the ignition
50. ase DTCs Turn the ignition off Turn the ignition on Start the engine With the DRBIII read DTCs Does this DTC reset Yes GoTo 2 GoTo 6 Turn the ignition off Disconnect the CAB harness connector Inspect the CAB 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 GoTo 3 Turn the ignition off Disconnect the CAB harness connector Turn the ignition on Using a 12 volt test light connected to ground check the used Optional Equipment Relay Output circuit at the CAB harness connector NOTE The test light must illuminate brightly Compare the brightness to that of a direct connection to the battery Does the test light illuminate brightly Yes GoTo 4 No Repair the Fused Optional Equipment Relay Output circuit for high resistance Perform ABS VERIFICATION TEST VER 1 77 BRAKES SYSTEM UNDERVOLTAGE Continued ACTION APPLICABILITY Turn the ignition off All Disconnect the CAB harness connector Using a 12 volt test light connected to ground check both Fused circuits at the CAB harness connector NOTE The test light must illuminate brightly Compare the brightness to that of a direct connection to the battery Does the test light illuminate brightly Yes GoTo 5 No Repair the Fused B circuit for high resistanc
51. ateral Acceleration Sensor ground circuit Measure the resistance of the 4 Lateral Acceleration Sensor signal circuits 15 the resistance above 5 0 ohms for any of the circuits Yes Repair the Lateral Acceleration Sensor circuit s for an open No GoTo 6 Turn the ignition off Disconnect the Lateral Acceleration Sensor harness connector Inspect the harness and connectors related to this circuit If any problems are found repair as necessary If no problems are found replace the Lateral Acceleration Sensor in accordance with the Service Information With the DRBIII9 clear DTCs With the DRBIII9 perform the road test procedure With the read DTCs Does this DTC reset Yes Replace the CAB in accordance with the Service Information No Test Complete 37 BRAKES LATERAL ACCELERATION SENSOR CIRCUIT Continued ACTION APPLICABILITY All The condition that set this DTC is not present at this time Monitor the DRBIII9 while wiggle testing the related harness and connectors Look for any related parameters to change or for the DTC to reset Inspect the related harness and connectors Look for any chafed pierced pinched or partially broken wires Look for broken bent pushed out or corroded terminals Were any problems found Yes Repair as necessary No Test Complete 38 BRAKES Symptom LATERAL ACCELERATION SENSOR INTERNAL FAULT POSSIBLE C
52. attery Does the test light illuminate brightly Yes GoTo 4 Repair the Fused Optional Equipment Relay Output circuit for an open Perform ABS VERIFICATION TEST VER 1 Turn the ignition off Disconnect the CAB harness connector Using 12 volt test light connected to ground check both used B circuits at the CAB harness connector NOTE The test light must illuminate brightly Compare the brightness to that of a direct connection to the battery Does the test light illuminate brightly Yes GoTo 5 No Repair the Fused B circuit for an open Perform ABS VERIFICATION TEST VER 1 Turn the ignition off Disconnect the CAB harness connector Using a 12 volt test light connected to 12 volts check the CAB harness connector Ground circuits NOTE The test light must illuminate brightly Compare the brightness to that of a direct connection to the battery Does the test light illuminate brightly Yes Replace the Controller Antilock Brake in accordance with the Service Information Perform ABS VERIFICATION TEST VER 1 No Repair the 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 Look for broken bent pushed out or corroded terminals Were any problems found Yes Repair as necessary Perform ABS VERIFICATION TEST VER 1 No
53. aulic control unit to develop the brake pressure 3 4 TCS ASR The primary function of the Traction Control System is to reduce wheel slip and maintain traction at the driven wheels when the road surfaces are slippery The Traction Control System reduces wheel slip by applying the brake that has lost traction The system is designed to operate at speeds below 50 km h 30 mph The engine s torque can be reduced by the ECM via the CAN C Bus if necessary The TCS can be deactivated with switch on the dash The Traction Control System uses the ABS to indicate spinning tires to enable the traction control function The TCS software is in the CAB The TCS ASR performs the following functions 1 Engine power derate 2 Engine deceleration regulation If the vehicle is on a patch of ice the simple action of releasing thethrottle is enough to causethe rear wheels to slip To avoid this thethrottleinput is regulated so power drops slowly instead of abruptly The engine power is reduced decelerated as neces sary 3 5 ELECTRONIC BRAKE DISTRIBUTION EBD The system was enhanced and eliminates the need the ALB system load sensing valve ESP equipped models will not have ALB The EBV system self adapts to operating conditions It de tects the vehicle s payload when the vehicle starts and pulls away Based on the acceleration rate when the vehicle first pulls away from a standstill the system is able to calculate the act
54. by more than 5 degrees Turn the ignition on With the DRBIII erase DTCs Test drive the vehide Using the DRBIII perform the road test procedure With the DRBIII9 read DTCs NOTE If the ESP lamp remains illuminated after the test has completed fault code will be set indicating the cause of the failure Does this DTC reset Yes GoTo 2 No GoTo 3 NOTE When the vehicle is in a turn the ESP compares the Steering Angle Sensor value and the speed of the inner and outer wheels to determine if the values are plausible Inspect the front end and steering components for damage or misalignment Inspec the steering column and Steering Angle Sensor for correct mounting and installation Inspect the tires and wheels to make sure that they correct size All tires must be the same size Inspect the left and right Wheel Speed Sensors to make sure they are connected correctly i e left harness connected to left sensor etc Were any problems found Yes Repair or replace components as necessary in accordance with the Service Information No ReplacetheSteering Angle Sensor in accordance with the Service Information 72 BRAKES STEERING ANGLE SENSOR IMPLAUSIBLE WHEEL SPEED Continued ACTION APPLICABILITY All The condition that set this DTC is not present at this time Monitor the DRBIII9 while wiggle testing the related harness and connectors Look for any related parameters
55. dance with the Service nformation Perform ABS VERIFICATION TEST VER 1 20 BRAKES Symptom CAB CHECK SUM When Monitored and Set Condition CAB CHECK SUM When Monitored Ignition On Once Set Condition When the sum of all storage bytes are not equal tothe original sum stored POSSIBLE CAUSES INTERMITTENT CAB CHECK SUM DTC DAMAGED CAB CAB HARNESS CONNECTOR FUSED OPTIONAL EQUIPMENT RELAY OUTPUT CIRCUIT OPEN FUSED B CIRCUIT OPEN GROUND CIRCUIT OPEN ANTI LOCK BRAKE CONTROLLER ACTION APPLICABILITY Turn the ignition on All With the DRBIII9 read DTCs With the DRBIII erase DTCs Turn the ignition off Turn the ignition on With the DRBIII read DTCs Does the DRBIII9 display CAB CHECK SUM Yes GoTo 2 No GoTo 6 Turn the ignition off Disconnect the CAB harness connector Inspect the CAB 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 3 21 BRAKES CAB CHECK SUM Continued ACTION APPLICABILITY Turn the ignition off Disconnect the CAB harness connector Turn the ignition on Using 12 volt test light connected to ground check the Fused Optional Equipment Relay Output circuit at the CAB harness connector NOTE The test light must illuminate brightly Compare the brightness to that of a direct connection to the b
56. e Perform ABS VERIFICATION TEST VER 1 Turn the ignition off Disconnect the CAB harness connector Using a 12 volt test light connected to 12 volts check the CAB harness connector Ground circuits NOTE The test light must illuminate brightly Compare the brightness to that of a direct connection to the battery Does the test light illuminate brightly Yes Replace the Controller Antilock Brake in accordance with the Service Information Perform ABS VERIFICATION TEST VER 1 No Repair the Ground circuit for high resistance 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 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 78 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 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 usin
57. e Information GoTo 3 Turn the ignition off Disconnect the Brake Fluid Level Switch harness connector Disconnect the Instrument Cluster C2 harness connector Measure the resistance between ground and the Brake Fluid Level Switch signal circuit 15 the resistance below 5 0 ohms Yes Repair the Brake Fluid Level Switch signal circuit for a short to ground No Replace the Antilock Brake Module in accordance with the Service nformation BRAKES BRAKE FLUID LEVEL Continued APPLICABILITY Turn the ignition off All Visually inspect the related wiring harness Look for any chafed pierced pinched or partially broken wires Look for broken bent pushed out or corroded terminals Were any problems found Yes Repair as necessary No Test Complete BRAKES Symptom BRAKE PRESSURE SENSOR CIRCUIT POSSIBLE CAUSES BRAKE PRESSURE SENSOR CIRCUIT INTERMITTENT DTC BRAKE PRESSURE SENSOR CIRCUIT SHORT TO VOLTAGE BRAKE PRESSURE SENSOR CIRCUIT SHORT TO GROUND BRAKE PRESSURE SENSOR CIRCUIT OPEN BRAKE PRESSURE SENSOR ANTI LOCK BRAKE CONTROLLER ACTION APPLICABILITY Turn the ignition off Turn the ignition on With the DRBIII9 read DTCs Record DTC information NOTE If a system undervoltage or overvoltage DTC is set along with this DTC diagnose the system voltage DTC first NOTE Before continuing make sure that the Brake Lamp switch is ad just
58. e engine speed above 2 000 5 Measure the voltage of both Fused B circuits in the CAB harness connector 15 the voltage below 9 4 volts Yes Repair the Fused circuit for an open Perform ABS VERIFICATION TEST VER 1 No GoTo 7 Turn the ignition off Disconnect the CAB harness connector Measure the voltage between the Fused circuit and both Ground circuits in the CAB harness connector 15 the voltage above 9 4 volts Yes Repair any charging system related DTCs before continuing If no charging system or system voltage DTCs are present in any module replace the Controller Antilock Brake in accordance with the Service Information Perform ABS VERIFICATION TEST VER 1 Repair the 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 Look for broken bent pushed out or corroded terminals Ensure the battery is fully charged Inspect the vehicle for aftermarket accessories that may exceed the Generator System output Were any problems found Yes Repair as necessary Perform ABS VERIFICATION TEST VER 1 No Test Complete 62 5 Symptom SOLENOID RELAY When Monitored and Set Condition SOLENOID RELAY When Monitored Ignition On Continuously Set Condition When there is a voltage deviation fro
59. e until either the resistance reading goes above 50 0 ohms or all modules that are connected to the CAN Bus are disconnected and the resistance reading remains below 50 0 ohms Then proceed to the conclusion question What is the outcome 50 0 ohms w all modules disconnected Repair the CAN C Bus circuit or the CAN C Bus circuit for a short to ground Perform BODY VERIFICATION TEST VER 1 250 0 ohms after disconnecting a module Replace the module that caused the resistance reading to increase after disconnecting it Perform BODY VERIFICATION TEST VER 1 50 BRAKES NO COMMUNICATION WITH BUS Continued ACTION APPLICABILITY Turn the ignition off All Disconnect the negative battery cable NOTE Refer to the wiring diagrams in the service information to help determine which modules are connected to the CAN Bus Disconnect all of the modules that are connected to the CAN Bus Measure the resistance between the CAN C Bus circuit and the CAN C Bus circuit at any disconnected module s harness connector 15 the resistance below ohms Yes Repair the CAN C Bus circuit for a short to the CAN C Bus circuit Perform BODY VERIFICATION TEST VER 1 GoTo 6 Turn the ignition off Reconnect the Engine Control Module harness connectors While back probing measure the resistance of the CAN C Bus circuit and the CAN C Bus circuit at the ECM harness connector 15 the resista
60. ed Ignition On Continuously Set Condition When the brake lamp switch and brake switch outputs are both open or shorted POSSIBLE CAUSES INTERMITTENT BRAKE SWITCH CIRCUIT DTC BRAKE LAMP SWITCH STATUS BRAKE SWITCH STATUS FUSED IGNITION SWITCH OUTPUT CIRCUIT OPEN OUTPUT CIRCUIT SHORT TO VOLTAGE OUTPUT CIRCUIT SHORT TO GROUND OUTPUT CIRCUIT OPEN BRAKE SWITCH OUTPUT CIRCUIT SHORT TO BRAKE LAMP SWITCH OUTPUT CIRCUIT BRAKE LAMP SWITCH BRAKE SWITCH ANTI LOCK BRAKE CONTROLLER APPLICABILITY NOTE This DTC will set if the Brake Switch the Brake Lamp Switch or All both switches are inoperative It will be necessary to verify the functional ity of each switch NOTE If the Brake Switch and the Brake Lamp Switch are inoperative it will be necessary to diagnose BOTH circuits Turn the ignition off Turn the ignition on With the DRBIII in Inputs Outputs monitor the Brake Lamp Switch state while pressing and releasing the brake pedal Does the DRBIII9 display change from OPEN to CLOSED as the brake pedal is pressed and released Yes GoTo 2 No GoTo 5 BRAKES BRAKE SWITCH CIRCUIT Continued ACTION APPLICABILITY NOTE This DTC will set if the Brake Switch the Brake Lamp Switch or both switches are inoperative It will be necessary to verify the functional ity of each switch NOTE If the Brake Switch and the Brake Lamp Switch are inoperative it will be necessary to diagnose BOTH circuit
61. ed correctly and functioning properly Adjust or replace the switch as necessary in accordance with the Service Information With the DRBIII erase DTCs Road test the vehicle and perform several braking maneuvers With the DRBIII read DTCs Does this DTC reset Yes GoTo 2 No GoTo 6 Turn the ignition off Disconnect the Brake Pressure Sensor harness connector Disconnect the CAB harness connector Turn the ignition on Measure the voltage of the Brake Pressure Sensor signal circuit Measure the voltage of the Brake Pressure Sensor ground circuit Measure the voltage of the Brake Pressure Sensor 5 volt supply circuit 15 there voltage present on any of the circuits Yes Repair the Brake Pressure Sensor circuit s for a short to voltage No GoTo 3 Turn the ignition off Disconnect the Brake Pressure Sensor harness connector Disconnect the CAB harness connector Measure the resistance between ground and the Brake Pressure Sensor signal circuit Measure the resistance between ground and the Brake Pressure Sensor 5 volt supply circuit Is the resistance below 5 0 ohms for either circuit Yes Repair the Brake Pressure Sensor circuit s for short to ground GoTo 4 BRAKES BRAKE PRESSURE SENSOR CIRCUIT Continued ACTION APPLICABILITY Turn the ignition off All Disconnect the Brake Pressure Sensor harness connector Disconnect the CAB harness connector Measure the re
62. es are applied during cornering the outer wheels get more of the vehicle s weight while the inner wheels get less weight and could lose traction wheel lock up The EBV system splits the pressure between left and right sides in addition to front and rear brakes 3 6 VEHICLE CONTROLLING FZR Vehicle controlling FZR requires additional sensors to operate The term ESP refers to the software of the system The term FZR refers to the system controller The TCS ASR system requires wheel speed sensors to monitor wheel slip and CAN bus communications to regulate engine power In addition to these inputs the vehicle controlling FZR requires a steering angle sensor and a lateral acceleration yaw rate sensor The ESP system does not take the vehicle load into account Instead the coefficient of friction is calculated in a 20 millisecond period where the controller measures the rate at which the wheel speed is decelerated as brake pressure is applied to the wheel 3 7 SYSTEM COMPONENTS Controller Antilock Brake Hydraulic Control Unit HCU Pump Motor Four Wheel Speed Sensors Tone Wheel assem blies ABS warning indicator e TCS ASR event indicator TCS ASR warning indicator e Steering Angle Sensor Lateral Acceleration Yaw Rate Sensor Brake Pressure Sensor ESP event indicator Brake Fluid Level switch Brake Switch BS Brake Lamp Switch BLS TCS S
63. essure during antilock braking or trac tion control events The CAB also has circuits that monitor the following Double brake switch outputs are monitored to determine whether or not to prepare for possible ABS 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 ABS braking Detect ABS system related problems and take diagnostic action e Able to execute self tests and output control com mands When equipped with Electronic Stability ESP the CAB also monitors the following TheESP looks at theSteeringAngle Sensor value and monitors the speed of the inner and outer wheels to ensure that the values are plausible The Steering Angle Sensor also monitors the speed that the steering wheel is turned The Lateral Acceleration Yaw Rate Sensor is con tained in one unit The sensor measures side to side lateral motion and rotational motion how fast the vehicle is turning The ESP uses data from the Brake Pressure Sensor to analyze how hard and fast that the driver wants to brake 3 7 8 HYDRAULIC CONTROL UNIT HCU The HCU on the Bosch 5 7 has an integral valve body for controlling the front and rear brakes Within the HCU are inlet outlet and shuttle valves to release brake pressure as required to avoid wheel lockup keeping the wheels rolling and maintain optimum deceleration with st
64. form ABS VERIFICATION TEST VER 1 53 BRAKES Symptom NO COMMUNICATION WITH IC ea When Monitored and Set Condition NO COMMUNICATION WITH IC When Monitored Ignition On Continuously Set Condition When the CAB fails to receive all messages from the IC POSSIBLE CAUSES NO COMMUNICATION WITH BUS DTC PRESENT INSTRUMENT CLUSTER DTC S PRESENT INSTRUMENT CLUSTER S POWER GROUND CIRCUIT S SHORTED OR OPEN BUS C BUS CIRCUIT S OPEN TO INSTRUMENT CLUSTER BUS C BUS CIRCUIT S OPEN CAB INSTRUMENT CLUSTER ANTI LOCK BRAKE CONTROLLER ACTION APPLICABILITY Turn the ignition on All With the DRBIII9 read CAB DTCs Does the DRBIII9 display NO COMMUNICATION WITH BUS Yes Refer to the symptom list for the appropriate diagnostic proce dure Perform ABS VERIFICATION TEST VER 1 GoTo 2 Turn the ignition on With the DRBIII9 read IC DTCs Does the DRBIII9 display any DTCs Yes Refer tolnstrument Cluster category for the related symptom s Perform ABS VERIFICATION TEST VER 1 GoTo 3 Turn the ignition on With the DRBIII9 check the and module for the same or similar No Communication with IC DTC Does the DRBIII9 display same or similar DTC in amp module Yes GoTo 4 No GoTo 6 54 5 NO COMMUNICATION WITH Continued APPLICABILITY Turn the ignition
65. g When measuring current connect the meter in series with test load When using the meter function keep the DRBIII9 away from spark plug or coil wires to avoid measuring error from outside interfer ence 4 3 WARNING 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 acddental 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 CAUTION 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 4 4 DIAGNOSIS 1 Your diagnostictest procedure must begin with a thorough visual inspect
66. g the DRBIII read DTC s from ALL modules 6 If any Diagnostic Trouble Codes are present return to Symptom list and troubleshoot new or recurring symptom 7 NOTE If the CAB HCU was replaced ensure the CAB has been initialized 8 NOTE If the SKREEM or ECM was replaced refer to the service information for proper programming procedures 9 NOTE For Sensor Circuit Signal and Pump Motor faults the CAB must sense all 4 wheels at 12 km h 8 mph before it will extinguish the ABS Indicator 10 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 11 CAUTION Ensure braking capability is available before road testing 12 Again with the DRBIII9 read If any DTC s are present return to Symptom list 13 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 Repair is not complete refer to appropriate symptom No Repair is complete 79 VERIFICATION TESTS Verification Tests Continued BODY VERIFICATION TEST VER 1 1 Disconnect all jumper wires and reconnect all previously disconnected components and connectors 2 Ensure that all accessories are turned off and the battery is fully charged 3 NOTE Refer to the service information for proper programming procedures if
67. gree with the info in the cluster If the cluster has been recently replaced refer to cluster reprogramming to ensure correct config uration before proceeding Using the DRBIII view the vehicle parameters entered into this module and the Instrument Cluster If possible correct any false information by performing the configuration functions with the scan tool If the information cannot be corrected using the DRBIII9 the module will need to be replaced Were any problems found Yes Repair as necessary No Test Complete 56 BRAKES Symptom PUMP MOTOR When Monitored and Set Condition PUMP MOTOR When Monitored Ignition On Continuously Set Condition When the pump motor voltage is not present after enabling the pump motor relay OR pump motor has voltage when the pump motor relay is disabled OR pump motor slow down test fails OR pump motor relay does not turn on completely POSSIBLE CAUSES INTERMITTENT PUMP MOTOR DTC DAMAGED CAB CAB HARNESS CONNECTOR FUSED OPTIONAL EQUIPMENT RELAY OUTPUT CIRCUIT OPEN FUSED B CIRCUIT OPEN GROUND CIRCUIT OPEN PUMP MOTOR ACTION APPLICABILITY NOTE If a system undervoltage or overvoltage DTC is set along with this All DTC diagnose the system voltage DTC first Turn the ignition on With the DRBIII9 read DTCs With the DRBIII erase DTCs Turn the ignition off Turn the ignition on With the DRBIII read DTCs Does the DRBIII9 display P
68. he Service Information Perform ABS VERIFICATION TEST VER 1 No Repair the 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 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 27 5 Symptom DRIVE TEST COMPLETED SUCCESSFULLY POSSIBLE CAUSES SYSTEM ROAD TEST COMPLETED SUCCESFULLY ACTION APPLICABILITY NOTE This is an informational DTC indicating that a fault free road test All procedure has been completed Turn the ignition on With the DRBIII clear DTCs Turn the ignition off Turn the ignition on With the DRBIII read DTCs Are any other DTCs set along with this DTC Yes Refer tothe Symptom List and perform the diagnostic procedure for any DTCs that are present No Test Complete 28 5 Symptom DRIVE TEST ERROR POSSIBLE CAUSES INTERMITTENT DRIVE TEST ERROR DTC STEERING COMPONENT INSPECTION LATERAL ACCELERATION SENSOR CIRCUIT SHORT TO VOLTAGE LATERAL ACCELERATION SENSOR CIRCUIT SHORT TO GROUND LATERAL ACCELERATION SENSOR CIRCUIT OPEN LATERAL ACCELERATION SENSOR ANTI LOCK BRAKE CONTROLLER ACTION APPLICABILITY Turn the ignition off All Turn the ignition on
69. ime Monitor the DRBIII9 while wiggle testing the related harness and connectors Look for any related parameters to change or for the DTC to reset Inspect the related harness and connectors Look for any chafed pierced pinched or partially broken wires Look for broken bent pushed out or corroded terminals Inspect thetires and wheels to make surethat they arethe correct size All tires must be the same size Inspect the steering column and Steering Angle Sensor for correct mounting and installation Inspect the front end and steering components for damage or misalignment Were any problems found Yes Repair as necessary No Test Complete 74 BRAKES Symptom SYSTEM OVERVOLTAGE POSSIBLE CAUSES INTERMITTENT DTC DAMAGED CAB CAB HARNESS CONNECTOR GROUND CIRCUIT OPEN ANTI LOCK BRAKE CONTROLLER APPLICABILITY NOTE Repair any Powertrain charging system DTCs before continuing All Turn the ignition on With the DRBIII9 read DTCs With the DRBIII erase DTCs Turn the ignition off Turn the ignition on Start the engine With the DRBIII9 read DTCs Does this DTC reset Yes GoTo 2 GoTo 4 Turn the ignition off Disconnect the CAB harness connector Inspect the CAB 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 GoTo
70. in Sensors read the Relay Output voltage Start the engine With the DRBIII in Sensors read the Relay Output voltage Select the Relay Output voltage that was displayed on the 119 Voltage below 9 4 volts GoTo 5 Voltage above 17 4 volts GoTo 7 Voltage between 9 4 and 17 4 volts GoTo 8 Turn the ignition off Disconnect the CAB harness connector Start the engine Allow the engine to idle WARNING WHEN THE ENGINE IS OPERATING DO NOT STAND IN A DIRECT LINE WITH THE FAN DO NOT PUT YOUR HANDS NEAR THE PULLEYS BELTS OR FAN DO NOT WEAR LOOSE CLOTHING Measure the voltage of the Fused Optional Equipment Relay Output circuit in the CAB harness connector Raise the engine speed above 2 000 5 Measure the voltage of the Fused Optional Equipment Relay Output circuit in the CAB harness connector 15 the voltage less than 9 4 volts Yes Repair theFused Optional Equipment Relay Output circuit for an open Perform ABS VERIFICATION TEST VER 1 GoTo 6 61 BRAKES RELAY OUTPUT VOLTAGE Continued APPLICABILITY Turn the ignition off All Disconnect the CAB harness connector Start the engine Allow the engine to idle WARNING WHEN THE ENGINE IS OPERATING DO NOT STAND INA DIRECT LINE WITH THE FAN DO NOT PUT YOUR HANDS NEAR THE PULLEYS BELTS OR FAN DO NOT WEAR LOOSE CLOTHING Measure the voltage of both Fused B circuits in the CAB harness connector Raise th
71. ion of the system in ques tion for damaged components or disconnected connectors For ABS the brake lamps must be operational prior to continuing 2 Connect the DRBIII9 to the data link connector located under the dash If the DRBIII9 does not power up check the power and ground supplies to the connector 3 Select the system in question Turn the ignition If the DRBIII9 displays No Response refer to Communication in the Body Diagnostic Pro cedures manual to diagnose the symptom 4 Read and record all diagnostic trouble codes If any additional codes are present proceed to the appropriate test 5 For ABS if there are no diagnostic trouble codes present select Inputs Outputs and read the Brake Switch and Brake Lamp Switch inputs as you press and release the brake pedal If the GENERAL INFORMATION display does not match the state of the pedal DC direct current perform the proper test For a problem with the ABS warning indicator refer tothe proper test DLC data link connector DRBIII diagnostic read out box 6 If no other problems are found it will be neces sary to road test the vehide THE DRBIII DTC diagnostic test code MUST NOT BE CONNECTED TO THE EBD electronic brake distribution DATA LINK CONNECTOR WHEN ROAD TESTING FOR PROPER ANTILOCK op ECM electronic control module ERATION THE SYSTEM IS DISABLED HCU hydraulic control unit WHILE IN DIAGNOSTIC MODE Perform yz Hertz several antilock stop
72. ircuits 15 the resistance above 5 0 ohms for any of the circuits Yes Repair the Lateral Acceleration Sensor circuit s an open No GoTo 6 Turn the ignition off Disconnect the Lateral Acceleration Sensor harness connector Inspect the harness and connectors related to this circuit If any problems are found repair as necessary If no problems are found replace the Lateral Acceleration Sensor in accordance with the Service Information With the clear DTCs With the DRBIII9 perform the road test procedure With the read DTCs Does this DTC reset Yes Replace the CAB in accordance with the Service Information No Test Complete 30 5 DRIVE TEST ERROR Continued ACTION APPLICABILITY All The condition that set this DTC is not present at this time Monitor the DRBIII9 while wiggle testing the related harness and connectors Look for any related parameters to change or for the DTC to reset Inspect the related harness and connectors Look for any chafed pierced pinched or partially broken wires Look for broken bent pushed out or corroded terminals Were any problems found Yes Repair as necessary No Test Complete 31 BRAKES Symptom INCORRECT TONE WHEEL When Monitored and Set Condition INCORRECT TONE WHEEL When Monitored Ignition On Continuously Set Condition When continuous ABS control is
73. ith Engine Control Module DTC Does the DRBIII display same or similar DTC in TCM IC amp ATC module Yes GoTo 4 No GoTo 6 52 BRAKES NO COMMUNICATION WITH ECM Continued ACTION APPLICABILITY Turn the ignition off All Disconnect the ECM harness connectors Check all of the 5 power circuits for a short or open condition Check all of the 5 ground circuits for an open condition Were any problems found Yes Repair the power ground circuit s as necessary Perform ABS VERIFICATION TEST VER 1 GoTo 5 Turn the ignition off Disconnect the ECM harness connectors Measure the resistance between the CAN Bus circuit and the CAN Bus circuit in the ECM harness connector 15 the resistance 57 to 63 ohms Yes Replace the Engine Control Module in accordance with the Service nformation Perform ABS VERIFICATION TEST VER 1 No Repair the CAN C Bus Bus circuit s for an open Perform ABS VERIFICATION TEST VER 1 Turn the ignition off Disconnect the CAB harness connector Measure the resistance between the CAN C Bus circuit and the CAN C Bus circuit in the CAB harness connector Is the resistance 57 to 63 ohms Yes Replace the Controller Antilock Brake in accordance with the Service Information Perform ABS VERIFICATION TEST VER 1 No Repair the CAN C Bus Bus 5 for an open Per
74. lure condition or symptom being present at time of diagnosis Please follow the recommendations below when choosing your diagnostic path 1 First make DRBIII9 is communicating with the vehicle system being diagnosed If the DRBIII9 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 iden tified locate the matching test in the Table of Contents and begin to diagnose the system All component location views are in Section 8 0 All connector pinouts in Section 9 0 All sche matics in Section 10 0 When repairs are required refer to the appropri ate service manual for the proper removal and repair procedure Diagnostic procedures change every year New diagnostic systems may be added carryover sys tems maybe enhanced READ THIS MANUAL BE FORE TRYING TO DIAGNOSE A VEHICLE DI AGNOSTIC TROUBLE CODE It is recommended that you review the entire manual to become famil iar with all new and changed diagnostic procedures This manual reflects many suggested changes from readers of past issues After using this man ual if you have any comments or recommendations please fill out the form at the back of the manual and mail it back 1 1 SYSTEM COVERAGE This diagnostic procedure manual covers the An tilock Braking System ABS
75. m the expected result of a CAB internal self check POSSIBLE CAUSES INTERMITTENT SOLENOID RELAY DTC DAMAGED CAB CAB HARNESS CONNECTOR FUSED OPTIONAL EQUIPMENT RELAY OUTPUT CIRCUIT OPEN FUSED B CIRCUIT OPEN GROUND CIRCUIT OPEN ANTI LOCK BRAKE CONTROLLER ACTION APPLICABILITY Turn the ignition on All With the DRBIII9 read DTCs With the DRBIII erase DTCs Turn the ignition off Turn the ignition on With the DRBIII9 read DTCs Does the DRBIII9 display SOLENOID RELAY Yes GoTo 2 No GoTo 6 Turn the ignition off Disconnect the CAB harness connector Inspect the CAB 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 3 63 BRAKES SOLENOID RELAY Continued APPLICABILITY Turn the ignition off Disconnect the CAB harness connector Turn the ignition on Using 12 volt test light connected to ground check the Fused Optional Equipment Relay Output circuit at the CAB harness connector NOTE The test light must illuminate brightly Compare the brightness to that of a direct connection to the battery Does the test light illuminate brightly Yes GoTo 4 Repair the F used Optional Equipment Relay Output circuit for an open Perform ABS VERIFICATION TEST VER 1 Turn the ignition off All Disconnect the CAB harness connector
76. nce 120 0 2 0 ohms Yes Replacethe Sentry Key Remote Entry Modulein accordance with the Service Information Perform BODY VERIFICATION TEST VER 1 Replace the Engine Control Module in accordance with the Service I nformation Perform BODY VERIFICATION TEST VER 1 51 BRAKES Symptom NO COMMUNICATION WITH ECM When Monitored and Set Condition NO COMMUNICATION WITH ECM When Monitored Ignition On Continuously Set Condition When the CAB fails to receive all messages from the ECM POSSIBLE CAUSES NO COMMUNICATION WITH BUS ENGINE CONTROL MODULE DTC S PRESENT ENGINE CONTROL MODULE S POWER GROUND CIRCUIT S SHORTED OR OPEN BUS C BUS CIRCUIT S OPEN TO ENGINE CONTROL MODULE CAN C BUS C BUS CIRCUIT S OPEN CAB ANTI LOCK BRAKE CONTROLLER ENGINE CONTROL MODULE ACTION APPLICABILITY Turn the ignition on All With the DRBIII9 read CAB DTCs Does the DRBIII9 display NO COMMUNICATION WITH BUS Yes Refer to the symptom list for the appropriate diagnostic proce dure Perform ABS VERIFICATION TEST VER 1 GoTo 2 Turn the ignition on With the DRBIII9 read ECM DTCs Does the DRBIII9 display any DTCs Yes Refer to Powertrain Diagnostic information for the related symp tom s Perform ABS VERIFICATION TEST VER 1 GoTo 3 Turn the ignition on With the DRBIII9 check the TCM IC and ATC module for the same or similar No Communication w
77. ns that may cause speed variations from wheel to wheel Were any problems found Yes Repair as necessary Perform ABS VERIFICATION TEST VER 1 No Test Complete 48 5 Symptom NO COMMUNICATION WITH BUS When Monitored and Set Condition NO COMMUNICATION WITH BUS When Monitored Ignition On Continuously Set Condition When the CAB fails to receive all module messages POSSIBLE CAUSES CAN CIRCUITS SHORTED TO VOLTAGE MODULE SHORT TO VOLTAGE CAN CIRCUITS SHORTED TO GROUND MODULE SHORT TO GROUND CAN CIRCUITS SHORTED TOGETHER ENGINE CONTROL MODULE SENTRY KEY REMOTE ENTRY MODULE APPLICABILITY Turn the ignition off All Disconnect the Instrument Cluster harness connectors Turn the ignition on Measure the voltage between CAN C Bus circuit and ground Measure the voltage between CAN C Bus circuit and ground 15 the voltage above 3 0 volts on either circuit Yes GoTo 2 GoTo 3 49 BRAKES NO COMMUNICATION WITH BUS Continued ACTION APPLICABILITY Turn the ignition off All Using a voltmeter connect one to the CAN circuit that previously measured above 3 0 volts and the other end to ground NOTE Refer to the wiring diagrams in the service information to help determine which modules are connected to the CAN Bus NOTE Wait one minute after turning the ignition off before disconnecting the module Disconnect a module tha
78. o 6 Turn the ignition off Disconnect the CAB harness connector Inspect the CAB 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 GoTo 3 Turn the ignition on Using a 12 volt test light connected to ground check the Fused Optional Equipment Relay Output circuit at the CAB harness connector NOTE The test light must illuminate brightly Compare the brightness to that of a direct connection to the battery Does the test light illuminate brightly Yes GoTo 4 No Repair the Fused Optional Equipment Relay Output circuit for an open Perform ABS VERIFICATION TEST VER 1 Turn the ignition off Disconnect the CAB harness connector Using 12 volt test light connected to ground check both Fused circuits at the CAB harness connector NOTE The test light must illuminate brightly Compare the brightness to that of a direct connection to the battery Does the test light illuminate brightly Yes GoTo 5 No Repair the Fused B circuit for an open Perform ABS VERIFICATION TEST VER 1 Turn the ignition off All Disconnect the CAB harness connector 41 BRAKES LEFT FRONT INLET SOLENOID Continued APPLICABILITY Turn the ignition off All Disconnect the CAB harness connector Using a 12 volt test light connected to 12 volts check
79. off Measure all the tire circumferences Do all the tire circumferences match Yes GoTo 4 No Repair as necessary Perform ABS VERIFICATION TEST VER 1 Turn the ignition off Inspect the tone wheel s for damage missing teeth cracks or looseness NOTE Refer to the service manual information if necessary for procedures or specifications Are or more tone wheel s loose or damaged Yes Repair as necessary Perform ABS VERIFICATION TEST VER 1 No GoTo 5 Turn the ignition off Visually inspect the brakes for locking up duetolining contamination or overheating Inspect all brake components for any condition that would cause a variation in wheel speed 15 any component damaged Yes Repair as necessary Perform ABS VERIFICATION TEST VER 1 No GoTo 7 Turn the ignition on With the DRBIII in Sensors monitor ALL the Wheel Speed Sensor signals while assistant drives the vehicle Slowly accelerate from a stop to 65 km h 40 mph NOTE Wheel Speed should not vary by more than 10 from wheel to wheel when driving in a straight line Do any of the Wheel Speed Sensor signals vary by greater than 10 while driving in a straight line Yes GoTo 8 Turn the ignition off Inspect the wheel bearings for excessive runout clearance NOTE Refer to the service information if necessary for procedures or specifications Is the wheel bearing clearance within specifications
80. off All Disconnect the harness connectors Check all of the C s power circuits for a short or open condition Check all of the C s ground circuits an open condition Were any problems found Yes Repair the power ground circuit s as necessary Perform ABS VERIFICATION TEST VER 1 No GoTo 5 Turn the ignition off Disconnect the I C harness connectors Measure the resistance between the CAN C Bus circuit and the CAN C Bus circuit in the harness connector 15 the resistance 57 to 63 ohms Yes Replace the Instrument Cluster in accordance with the Service Information Perform ABS VERIFICATION TEST VER 1 Repair the CAN Bus J CAN C Bus circuit s for an open Perform ABS VERIFICATION TEST VER 1 Turn the ignition off Disconnect the CAB harness connector Measure the resistance between the CAN C Bus circuit and the CAN C Bus circuit in the CAB harness connector Is the resistance 57 to 63 ohms Yes Replace the Controller Antilock Brake in accordance with the Service Information Perform ABS VERIFICATION TEST VER 1 No Repair the CAN C Bus C Bus 5 for an open Perform ABS VERIFICATION TEST VER 1 55 5 Symptom PARAMETERIZATION ERROR POSSIBLE CAUSES PARAMETERIZATION ERROR ACTION APPLICABILITY NOTE DTC indicates the ABM has not been configured or that the info in All the module does not a
81. on on Measure the voltage on all 4 of the Lateral Acceleration Sensor signal circuits Measure the voltage of the Lateral Acceleration Sensor ground circuit There should be no voltage present on any of the circuits Measure the resistance between the Lateral Acceleration supply circuit and all 4 of the Lateral Acceleration Sensor signal circuits The resistance between the circuits should be above 5 0 ohms Were there any problems found Yes Repair the shorted Lateral Acceleration Sensor circuit s No GoTo 4 Turn the ignition off Disconnect the Lateral Acceleration Sensor harness connector Disconnect the CAB harness connector Measure the resistance between the Lateral Acceleration Sensor ground and the 4 Lateral Acceleration Sensor signal circuits Measure the resistance between ground and the 4 Lateral Acceleration Sensor signal circuits Measure the resistance between ground and the Lateral Acceleration Sensor supply circuit 15 the resistance below 5 0 ohms for any of the circuits Yes Repair the Lateral Acceleration Sensor circuit s for a short to ground GoTo 5 Turn the ignition off Disconnect the Lateral Acceleration Sensor harness connector Disconnect the CAB harness connector Measure the resistance of the Lateral Acceleration Sensor supply circuit Measure the resistance of the Lateral Acceleration Sensor ground circuit Measure the resistance of the 4 Lateral Acceleration Sensor signal c
82. r Requested COLD Boot Press MORE to switch between this display and the application screen Press F4 when done noting information DOES NOT POWER UP BLANK SCREEN If the LED s donot 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 16 way connector cavity 16 A minimum of 11 volts is required to adequately power the DRBIII Also check for a good ground at DLC If all connections are proper between the DRBIII9 and the vehicle or other devices and the vehide battery is fully charged an inoperative DRBIII may be the result or a faulty cable or vehide wiring 3 9 2 DISPLAY IS NOT VISIBLE Low temperatures will affect the visibility of the display Adjust the contrast to compensate for this condition 3 9 1 DISPLAY REPLACEABLE LENS ENTER KEYS NA LEDs CONTRAST with YES key BACK LIGHTING OOD with YES key Qoo KEYPAD SHIFT KEY LED 80b57566 4 0 DISCLAIMERS SAFETY WARNINGS 4 1 DISCLAIMERS information illustrations and specifications contained in this manual are based on the latest GENERAL INFORMATION 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
83. ration Sensor harness connector Disconnect the CAB harness connector Turn the ignition on Measure the voltage on all 4 of the Lateral Acceleration Sensor signal circuits Measure the voltage of the Lateral Acceleration Sensor ground circuit There should be no voltage present on any of the circuits Measure the resistance between the Lateral Acceleration supply circuit and all 4 of the Lateral Acceleration Sensor signal circuits The resistance between the circuits should be above 5 0 ohms Were there any problems found Yes Repair the Lateral Acceleration Sensor circuit s for a short to voltage GoTo 4 Turn the ignition off Disconnect the Lateral Acceleration Sensor harness connector Disconnect the CAB harness connector Measure the resistance between the Lateral Acceleration Sensor ground and the 4 Lateral Acceleration Sensor signal circuits Measure the resistance between ground and the 4 Lateral Acceleration Sensor signal circuits Measure the resistance between ground and the Lateral Acceleration Sensor supply circuit Is the resistance below 5 0 ohms for any of the circuits Yes Repair the Lateral Acceleration Sensor circuit s for a short to ground GoTo 5 Turn the ignition off Disconnect the Lateral Acceleration Sensor harness connector Disconnect the CAB harness connector Measure the resistance of the Lateral Acceleration Sensor supply circuit Measure the resistance of the L
84. s Turn the ignition off Turn the ignition on With the DRBIII Inputs Outputs monitor the Brake Switch state while pressing and releasing the brake pedal Does the DRBIII9 display change from CLOSED to OPEN as the brake pedal is pressed and released Yes GoTo 3 No GoTo 4 Turn the ignition off Visually inspect the related wiring harness Look for any chafed pierced pinched or partially broken wires 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 Turn the ignition on With the DRBIII9 in Inputs Outputs monitor the Brake Switch state Connect a jumper wire between the Fused Ignition Switch Output circuit and Brake Switch Output circuit in the C1 Brake Switch harness connector Does the DRBIII9 display a change from OPEN to CLOSED Yes Replace the Brake Switch in accordance with the Service Infor mation Perform ABS VERIFICATION TEST VER 1 GoTo 6 Turn the ignition off Disconnect the C2 Brake Lamp Switch harness connector Turn the ignition on With the DRBIII in Inputs Outputs monitor the Brake Lamp Switch state Connect a jumper wire between the Fused Ignition Switch Output circuit and Brake Lamp Switch Output circuit in the C2 Brake Lamp Switch harness connector Does the DRBIII9 display a change from OPEN to CLOSED Yes Replace the Brake Lamp Switch in
85. s from above 50 Km h 30 t dust mph and then repeat steps 2 3 and 4 If any instrument cluster diagnostic trouble codes are present proceed to LF left front the appropriate test LR left rear 7 The following conditions should be considered PM pump motor NORMAL operation and no repairs should be attempted to correct them RF right front Brake pedal feedback during ABS stop RR right rear dicking vibrating SOL solenoid Clicking groaning or buzzing at 12 Km h 8 TCS traction control system Hi drive i pie nbus TCSS traction control system switch dii RUM 98 VSS vehicle speed signal Slight brake pedal drop and pop noise when ignition is initially turned on WSS wheel speed sensor 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 DRBIII9 diagnostic read out box jumper wires ohmmeter voltmeter test light oscilloscope 6 0 GLOSSARY OF TERMS ABS antilock brake system AC alternating current BCM body control module BS brake switch BLS brake lamp switch CAB controller antilock brake NOTES 7 0
86. s tells the CAB what position the brake pedal is currently in to make an ABS event possible When using the DRBIII9 in Inputs Outputs the BS and BLS will read opposite switch states Note The BS and BLS are in the same switch housing TRACTION CONTROL SYSTEM SWITCH TCSS Thisswitch signalsthe CAB toeither turn ON or OFF the TCS The driver can toggle the TCSS which receives 12 volts from the D Relay Output circuit Depending on the position of the TCSS open or closed the CAB receives the TCSS state voltage on the TCS Switch Sense circuit When 12 volts are applied tothe TCS Switch Sense circuit the TCS is OFF When no voltageis present the TCS is ON WHEEL SPEED SENSORS AND TONE WHEELS The Bosch 5 7 system uses one passive WSS on each wheel sensor measures the wheel speed by monitoring a rotating tone wheel As the teeth of the tone wheel move through the magnetic field of the sensor an AC voltage and amperage is generated This signal frequency increases or de creases proportionally to the speed of the wheel The CAB monitors this signal to check a sudden change in single or multiple wheel decelerations If the deceleration of one or more wheels is not within a predetermined amount the CAB takes control for antilock action through the HCU Each WSS has a magnetic inductive pick up coil WSS that is mounted to a fixed component There is an air gap between the tone wheel and the speed sensor as sembly Diagno
87. sistance of the Brake Pressure Sensor signal circuit Measure the resistance of the Brake Pressure Sensor ground circuit Measure the resistance of the Brake Pressure Sensor 5 volt supply circuit Is the resistance above 5 0 ohms for any of the circuits Yes Repair the Brake Pressure Sensor circuit s for an open No GoTo 5 Turn the ignition off Disconnect the Brake Pressure Sensor harness connector Inspect the harness and connectors related to this circuit If any problems are found repair as necessary If no problems are found replace the Brake Pressure Sensor in accordance with the Service Information With the DRBIII clear DTCs Road test the vehicle and perform several braking maneuvers With the DRBIII9 read DTCs Does this DTC reset Yes Replace the CAB in accordance with the Service Information No Test Complete The condition that set this DTC is not present at this time Monitor the DRBIII while wiggle testing the related harness and connectors Look for any related parameters to change or for the DTC to reset Inspect the related harness and connectors Look for any chafed pierced pinched or partially broken wires Look for broken bent pushed out or corroded terminals Were any problems found Yes Repair as necessary No Test Complete 16 BRAKES Symptom BRAKE SWITCH CIRCUIT When Monitored and Set Condition BRAKE SWITCH CIRCUIT When Monitor
88. ss connector 15 the resistance below 5 0 ohms Yes Repair the affected Wheel Speed Sensor circuit for a short to ground Perform ABS VERIFICATION TEST VER 1 GoTo 5 Turn the ignition off Disconnect the CAB harness connector Measure the resistance between the affected Wheel Speed Sensor circuits in the CAB harness connector Is the resistance over 1 800 ohms Yes Repair the affected Wheel Speed Sensor circuit for an open Perform ABS VERIFICATION TEST VER 1 No GoTo 6 Turn the ignition off Disconnect the CAB harness connector Measure the resistance between the affected Wheel Speed Sensor circuits in the CAB harness connector 15 the resistance under 1 100 ohms Yes Repair the affected Wheel Speed Sensor circuits for a short to each other Perform ABS VERIFICATION TEST VER 1 Replace the Controller Antilock Brake in accordance with the Service nformation Perform ABS VERIFICATION TEST VER 1 44 BRAKES LEFT FRONT WHEEL SPEED SENSOR CIRCUIT Continued APPLICABILITY Turn the ignition off All Visually inspect the related wiring harness Look for any chafed pierced pinched or partially broken wires 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 45 BRAKES Symptom List LEFT FRONT WHEEL SPEED SENSOR SIG
89. stically the coils of the Wheel Speed Sensors have the same amount of resistance When measured across the CAB harness connector termi nals the resistance should be between 1100 1800 ohms Refer to service manual for WSS replacement and air gap specifications Correct ABS operation is dependent on Tone Wheel speed signal from the WSS The vehicle wheels and tires should all be the same size and type to get accurate signals In addition all tires should be at recommended tire pressures 3 7 5 SELF TESTS The system software includes several self tests that are performed every time the ignition is turned on and the vehicle is driven Some of the self tests occur immediately while others occur under normal driving conditions while not in antilock operation The CAB checks continuously for a missing or erratic WSS signals circuits tone wheels solenoids pump motor or solenoid relay by performing several tests such as dynamic static ohmic voltage drop and timed response If any component exhibits a fault during testing the CAB will request to illumi nate the ABS and TCS warning indicators As an additional check of the ESP system a road test procedure is available on the DRBIII This test should be carried out when any ESP component is replaced in order to ensure proper function Since the wheel speed sensors are required inputs to the ESP this test should also be performed if the wheel speed sensors are replaced First the
90. switch output circuit at the switch connector NOTE Measurement is taken at the Brake Switch Output circuit or the Brake Lamp Output circuit as determined by the previously performed switch test Is the resistance below 5 0 ohms Yes Repair the affected circuit a short to ground Perform ABS VERIFICATION TEST VER 1 No GoTo 9 Turn the ignition off Disconnect the CAB harness connector Disconnect the appropriate brake switch harness connector Measure the resistance of the output circuit between the switch harness connector and the CAB harness connector NOTE Measurement is taken at the Brake Switch Output circuit or the Brake Lamp Output circuit as determined by the previously performed switch test Is the resistance above 5 0 ohms Yes Repair the affected circuit for an open Perform ABS VERIFICATION TEST VER 1 No GoTo 10 19 BRAKES BRAKE SWITCH CIRCUIT Continued ACTION APPLICABILITY Turn the ignition off All Disconnect the CAB harness connector Disconnect the C1 Brake Switch and C2 Brake Lamp Switch harness connectors Measure the resistance between the Brake Switch Output circuit and Brake Lamp Switch Output circuit in the C1 and C2 connectors Is the resistance below 5 0 ohms Yes Repair the Brake Switch Output circuit for a short to the Brake Lamp Switch Output circuit Perform ABS VERIFICATION TEST VER 1 Replace the Controller Antilock Brake in accor
91. t is connected to the CAN bus Turn the ignition on Monitor and note the voltmeter reading Repeat this procedure until either the voltage reading drops below 3 0 volts or all modules that are connected tothe CAN Bus are disconnected and the voltage reading remains above 3 0 volts Then proceed to the conclusion question What is the outcome gt 3 0 volts w all modules disconnected Repair the CAN C Bus circuit or the CAN Bus circuit for a short to voltage Perform BODY VERIFICATION TEST VER 1 3 0 volts after disconnecting a module Replace the module that caused the voltage reading to drop after disconnecting it Perform BODY VERIFICATION TEST VER 1 Turn the ignition off Disconnect the Instrument Cluster harness connectors Disconnect the negative battery cable Measure the resistance between ground and the CAN C Bus circuit Measure the resistance between ground and the CAN C Bus circuit 15 the resistance below 50 0 ohms on either circuit Yes GoTo 4 No GoTo 5 Turn the ignition off Disconnect the negative battery cable Using an ohmmeter connect end to the CAN Bus that previously measured below 50 0 ohms and the other end to ground NOTE Refer to the wiring diagrams in the service information to help determine which modules are connected to the CAN Bus Disconnect a module that is connected to the CAN Bus Monitor and note the ohmmeter reading Repeat this procedur
92. the CAB harness connector Ground circuits NOTE The test light must illuminate brightly Compare the brightness to that of a direct connection to the battery Does the test light illuminate brightly Yes Replace the Controller Antilock Brake in accordance with the Service Information Perform ABS VERIFICATION TEST VER 1 Repair the 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 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 42 BRAKES Symptom List LEFT FRONT WHEEL SPEED SENSOR CIRCUIT LEFT REAR WHEEL SPEED SENSOR CIRCUIT RIGHT FRONT WHEEL SPEED SENSOR CIRCUIT RIGHT REAR WHEEL SPEED SENSOR CIRCUIT Test Note All symptoms listed above are diagnosed using the same tests The title for the tests will be LEFT FRONT WHEEL SPEED SENSOR CIRCUIT When Monitored and Set Condition LEFT FRONT WHEEL SPEED SENSOR CIRCUIT When Monitored Ignition On Continuously Set Condition When the value of the wheel speed sensor circuit is open or shorted POSSIBLE CAUSES INTERMITTENT WHEEL SPEED SENSOR CIRCUIT DTC DAMAGED CAB CAB HARNESS CONNECTOR WHEEL SPEED SENSOR CIRCUIT SHORT TO VOLTAGE WHEEL SPEED SENSOR CIRCUIT SHORT TO GROUND WHEEL S
93. ual payload This is a rough estimate which is used initially Later on the system gathers more precise informa tion by monitoring the brake pressure and wheel speed and negative slip when the driver applies the brakes The system will then produce a more accu rate calculation of payload depending on brake retardation The adaptation is erased when the ignition is switched off A new adaptation will occur on the next driving cycle By default the system acts upon the vehide as if in an unloaded condition safe mode Once a new driving cycle begins with the vehide in a fully loaded condition without having gathered more precise information the system will detect ABS actuation in the front wheels and will allow enough pressure to be applied to the rear axle to an extent where the wheels are just about to lock up maximum braking possible The system calculates the braking force at the front and rear axles If the driver applies the brakes gently and then realizes he needs to apply the brakes further the EBV allows the proper pressure to be applied to the front and rear brakes The EBV also contains a feature called corner brake system CBS which operates when the ve hide is braked while cornering to avoid a possible oversteering condition The EBV monitors the wheel speed of both rear wheels to detect when the vehicle is cornering and allows precise brake pres sure application to the front and rear brakes Also when the brak
94. witch TCSS K ABS CAN C Bus Fuses grounds and wiring 3 7 1 ABS AND TCS ASR INDICATORS This system is equipped with an ABS warning indicator TCS ASR warning indicator and TCS ASR event indicator to alert the driver of a malfunction event it has detected The CAB can request the illumination of the ABS warning indi cator TCS ASR warning indicator and TCS ASR event indicator via CAN C BUS The CAB controls the ABS warning indicator by e Light steady during an initial test at the begin ning of an ignition cycle to function as a bulb check e Light steady when a system malfunction exists DTC Light steady If you have not met the speed required to reset retest the ABS components Instrument Cluster controls the indica tors The Instrument Cluster transmits a message over the CAN C Bus relating to diagnostics and current lamp status for the ABS and TCS ASR indicators The CAB can control the operation of TCS warning and TCS event indicators by Both light steady with engine off and both go out with engine running TCS warning indicator lights steady when a TCS malfunction exists TCS event indicator will flash when TCS is in an active event 3 7 2 CONTROLLER ANTILOCK BRAKE CAB The CAB is mounted directly to the Hydraulic Control Unit HCU that indudes a microprocessor and twelve solenoids that control valves that con GENERAL INFORMATION trol brake pr
95. y by greater than 1096 while driving in a straight line Yes GoTo 2 GoTo 8 46 BRAKES LEFT FRONT WHEEL SPEED SENSOR SIGNAL Continued ACTION APPLICABILITY Turn the ignition off Inspect the CAB harness connector and affected Wheel Speed Sensor Inspect for looseness Inspect wiring harness Inspect for metal chips on sensor 15 the Wheel Speed Sensor or CAB harness connector damaged Yes Repair as necessary Perform ABS VERIFICATION TEST VER 1 No GoTo 3 Turn the ignition off Inspect the affected Wheel Speed Sensor s tone wheel for damage looseness or missing NOTE Refer to the appropriate Service information if necessary for procedures or specifications 15 the affected tone wheel OK Yes GoTo 4 No Replace the tone wheel in accordance with the Service Informa tion Perform ABS VERIFICATION TEST VER 1 Turn the ignition off Inspect the affected Wheel Speed Sensor s wheel bearing NOTE Refer to the appropriate Service information if necessary for procedures or specifications Is the affected wheel bearing dearance OK Yes GoTo 6 No Repair as necessary Perform ABS VERIFICATION TEST VER 1 Turn the ignition off Visually inspect the brakes for locking up duetolining contamination or overheating Inspect all brake components for defects which would cause a speed difference Were any problems found Yes Repair as necessary

2006 DODGE Sprinter Chassis Manual

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