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1.0
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1.1
SYSTEM COVERAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1.2
SIX-STEP TROUBLESHOOTING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . .1
2.0
IDENTIFICATION OF SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
3.0
SYSTEM DESCRIPTION AND FUNCTIONAL OPERATION . . . . . . . . . . . . . . . . . . . . . .1
3.1
TEVES MARK 20e SYSTEM DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
3.1.1
3.1.2
3.1.3
3.1.4
3.1.5
3.1.6
3.2
ABS DIAGNOSTIC TROUBLE CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
3.2.1
3.2.2
3.2.3
3.2.4
3.3
USING THE DRBIII . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
3.4
DRBIII ERROR MESSAGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
3.4.1
3.4.2
4.0
DISCLAIMERS, SAFETY, WARNINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
4.1
DISCLAIMERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
4.2
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
4.2.1
4.2.2
4.2.3
4.2.4
4.3
WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
4.3.1
4.3.2
4.4
5.0
REQUIRED TOOLS AND EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
6.0
GLOSSARY OF TERMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
7.0
DIAGNOSTIC INFORMATION AND PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
BRAKES (CAB)
BUS SYSTEM COMMUNICATION FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
CAB INTERNAL FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
CLUSTER LAMP FAILURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
G-SENSOR FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
LEFT FRONT SENSOR CIRCUIT FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
REAR SENSOR CIRCUIT FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
RIGHT FRONT SENSOR CIRCUIT FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
LEFT FRONT WHEEL SPEED SIGNAL FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
TABLE OF CONTENTS
PEDAL FEEL/VEHICLES CHARACTERISTICS . . . . . . . . . . . . . . . . . . .2
SYSTEM COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
ABS AND RED BRAKE WARNING INDICATOR . . . . . . . . . . . . . . . . . . .2
CONTROLLER ANTILOCK BRAKE (CAB) . . . . . . . . . . . . . . . . . . . . . . .2
HYDRAULIC CONTROL UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
SENSORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
SYSTEM INITIALIZATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
DIAGNOSTIC MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
INTERMITTENT DIAGNOSTIC TROUBLE CODES . . . . . . . . . . . . . . . .4
FREEZE FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
DRBIII DOES NOT POWER UP (BLANK SCREEN). . . . . . . . . . . . . . .4
DISPLAY IS NOT VISIBLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
TECHNICIAN SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . .5
VEHICLE PREPARATION FOR TESTING. . . . . . . . . . . . . . . . . . . . . . . .5
SERVICING SUB-ASSEMBLIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
DRBIII SAFETY INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
VEHICLE DAMAGE WARNINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
ROAD TESTING A COMPLAINT VEHICLE . . . . . . . . . . . . . . . . . . . . . . .6
DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
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Table of Contents
Related Manuals for Jeep KJ Liberty Cherokee 2003
Summary of Contents for Jeep KJ Liberty Cherokee 2003
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Page 1: Table Of Contents
TABLE OF CONTENTS INTRODUCTION ............1 SYSTEM COVERAGE . - Page 2 TABLE OF CONTENTS - Continued REAR WHEEL SPEED SIGNAL FAILURE ........22 RIGHT FRONT WHEEL SPEED SIGNAL FAILURE .
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Page 3: Introduction
The procedures contained in this manual include all the specifications, instructions, and graphics 2.0 IDENTIFICATION OF needed to diagnose the 2003 Jeep Liberty Mark 20e SYSTEM Antilock Braking System (ABS) problems. The di- agnostics in this manual are based on the failure... -
Page 4: Pedal Feel/Vehicles Characteristics
GENERAL INFORMATION wheel is locked. The antilock system maintains an • valve block assembly: 6 valve solenoids (3 inlet average of approximately 20% wheel slip. valves, 3 outlet valves) It is important to remember that the antilock 3 accumulators brake system does not shorten the vehicle stopping •... -
Page 5: Hydraulic Control Unit
GENERAL INFORMATION The CAB continuously monitors the wheel speed during antilock braking. The pump is supplied fluid sensors. When a wheel locking tendency is detected, that is released to the accumulators when the outlet the CAB will command the appropriate HCU valve valve is opened during an antilock stop. -
Page 6: Abs Diagnostic Trouble Codes
GENERAL INFORMATION braking. The G-Sensor is mounted inside the CAB • excessive axle shaft runout and is not separately serviceable. • hydraulic system leaks • regular brake system problems, non-ABS related 3.2 ABS DIAGNOSTIC TROUBLE CODES If no obvious problems are found, erase diagnostic trouble codes and with the key on, wiggle the wire The Teves Mark 20e Antilock Brake System harness and connectors. -
Page 7: Display Is Not Visible
GENERAL INFORMATION If all connections are proper between the important to block the wheels on front-wheel drive DRBIII and the vehicle or other devices, and the vehicles; the parking brake does not hold the front vehicle battery is fully charged, an inoperative drive wheels. -
Page 8: Warning
GENERAL INFORMATION Do not exceed the limits shown in the table below: CAUTION: Before road testing a vehicle, be sure that all components are reassembled. FUNCTION INPUT LIMIT During the test drive, do not try to read the Volts 0 - 500 peak volts AC DRBIII screen while in motion. -
Page 9: Required Tools And Equipment
9. After a road test in which no problems were hydraulic control unit found, refer to any Technical Service Bulletins that may apply. junction block JTEC Jeep and Truck Engine Controller 5.0 REQUIRED TOOLS AND left front EQUIPMENT left rear Programmable Communication In-... - Page 10 NOTES...
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Page 11: Diagnostic Information And Procedures
DIAGNOSTIC INFORMATION AND PROCEDURES... -
Page 12: Bus System Communication Failure
BRAKES (CAB) Symptom: BUS SYSTEM COMMUNICATION FAILURE When Monitored and Set Condition: BUS SYSTEM COMMUNICATION FAILURE When Monitored: Ignition on. Continuously monitors. Set Condition: When the CAB detects a short on the PCI Bus circuit. POSSIBLE CAUSES INTERMITTENT CONDITION ELECTRO-MECHANICAL INSTRUMENT CLUSTER DTC PRESENT BUS CIRCUIT OPEN CAB - INTERNAL FAILURE TEST... - Page 13 BRAKES (CAB) BUS SYSTEM COMMUNICATION FAILURE — Continued TEST ACTION APPLICABILITY 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.
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Page 14: Cab Internal Failure
BRAKES (CAB) Symptom: CAB INTERNAL FAILURE When Monitored and Set Condition: CAB INTERNAL FAILURE When Monitored: Ignition on. The CAB monitors its internal microprocessors for correct operation. Set Condition: If the CAB detects an internal fault, the DTC is set. POSSIBLE CAUSES INTERMITTENT DTC DAMAGED CAB/CAB HARNESS CONNECTOR... - Page 15 BRAKES (CAB) CAB INTERNAL FAILURE — Continued TEST ACTION APPLICABILITY Turn the ignition off. Using a 12-volt test light connected to ground, probe the ABS Valve Fused B(+) circuit at the CAB harness connector. Did the test light illuminate? Yes → Go To 5 →...
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Page 16: Cluster Lamp Failure
BRAKES (CAB) Symptom: CLUSTER LAMP FAILURE When Monitored and Set Condition: CLUSTER LAMP FAILURE When Monitored: Ignition on. Continuous. Set Condition: When the CAB receives a bus message from the Instrument Cluster that the Cluster cannot illuminate the ABS Warning Indicator. POSSIBLE CAUSES INSTRUMENT CLUSTER OR ABS DTC PRESENT INSTRUMENT CLUSTER... - Page 17 BRAKES (CAB) CLUSTER LAMP FAILURE — Continued TEST ACTION APPLICABILITY NOTE: The DRBIII communication with the CAB must be operational for the result of this test to be valid. Turn the ignition off. Remove ABS Valve fuse from the PDC. Perform the Key-on Bulb Check.
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Page 18: G-Sensor Failure
BRAKES (CAB) Symptom: G-SENSOR FAILURE When Monitored and Set Condition: G-SENSOR FAILURE When Monitored: Ignition ON. Continuously monitored when speed is greater than 2 km/h (1 mph) and there is no Brake Lamp Switch input. Set Condition: When the CAB detects a condition outside programmed parameters from the internal G-Sensor. -
Page 19: Left Front Sensor Circuit Failure
BRAKES (CAB) Symptom List: LEFT FRONT SENSOR CIRCUIT FAILURE REAR SENSOR CIRCUIT FAILURE RIGHT FRONT SENSOR CIRCUIT FAILURE Test Note: All symptoms listed above are diagnosed using the same tests. The title for the tests will be LEFT FRONT SENSOR CIRCUIT FAILURE. - Page 20 BRAKES (CAB) LEFT FRONT SENSOR CIRCUIT FAILURE — Continued TEST ACTION APPLICABILITY Turn the ignition on. With the DRBIII , read DTCs. With the DRBIII , read the Freeze Frame information. With the DRBIII , erase DTCs. Turn the ignition off. Turn the ignition on.
- Page 21 BRAKES (CAB) LEFT FRONT SENSOR CIRCUIT FAILURE — Continued TEST ACTION APPLICABILITY Turn the ignition off. Disconnect the CAB harness connector. Disconnect the affected Wheel Speed Sensor connector. Connect a jumper wire between affected Wheel Speed Sensor 12 Volt Supply circuit and ground.
- Page 22 BRAKES (CAB) LEFT FRONT SENSOR CIRCUIT FAILURE — Continued TEST ACTION APPLICABILITY Turn the ignition off. Remove the CAB harness strain relief to access wires. Reconnect the CAB harness connector. Turn the ignition on. Measure the voltage between affected Wheel Speed Sensor 12 Volt Supply circuit and ground.
- Page 23 BRAKES (CAB) LEFT FRONT SENSOR CIRCUIT FAILURE — Continued TEST ACTION APPLICABILITY 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.
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Page 24: Left Front Wheel Speed Signal Failure
BRAKES (CAB) Symptom List: LEFT FRONT WHEEL SPEED SIGNAL FAILURE REAR WHEEL SPEED SIGNAL FAILURE RIGHT FRONT WHEEL SPEED SIGNAL FAILURE Test Note: All symptoms listed above are diagnosed using the same tests. The title for the tests will be LEFT FRONT WHEEL SPEED SIGNAL FAILURE. - Page 25 BRAKES (CAB) LEFT FRONT WHEEL SPEED SIGNAL FAILURE — Continued POSSIBLE CAUSES BRAKE LINING FAULT AFFECTED WHEEL SPEED SENSOR CIRCUIT ELECTRICAL FAULT TEST ACTION APPLICABILITY Turn the ignition on. With the DRBIII , read DTCs. With the DRBIII , read Freeze Frame information. NOTE: The CAB must sense ALL 4 wheels at 25 km/h (15 mph) before it will extinguish the ABS indicators.
- Page 26 BRAKES (CAB) LEFT FRONT WHEEL SPEED SIGNAL FAILURE — Continued TEST ACTION APPLICABILITY Turn the ignition off. Using a Feeler Gauge, measure the affected Wheel Speed Sensor Air Gap. NOTE: Refer to the appropriate service information, if necessary, for procedures or specifications. Is the Air Gap OK? Yes →...
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Page 27: Pump Circuit Failure
BRAKES (CAB) Symptom: PUMP CIRCUIT FAILURE When Monitored and Set Condition: PUMP CIRCUIT FAILURE When Monitored: Ignition on. The CAB commands the pump on at 20 km/h (12 mph) to check its operation, if the brake switch is not applied. If the brake is applied, the test will run at 40 km/h (25 mph). - Page 28 BRAKES (CAB) PUMP CIRCUIT FAILURE — Continued TEST ACTION APPLICABILITY Turn the ignition off. Turn the ignition on. With the DRBIII , read DTCs. With the DRBIII , erase DTCs. Turn the ignition off. Turn the ignition on. With the DRBIII , actuate the ABS Pump Motor. Did the ABS Pump Motor operate? Yes →...
- Page 29 BRAKES (CAB) PUMP CIRCUIT FAILURE — Continued TEST ACTION APPLICABILITY Turn the ignition off. Reconnect the CAB harness connector. Using a 12-volt test light connected to 12-volts, probe the ABS Pump Fused B(+) circuit fuse terminal. Does the test light illuminate? Yes →...
- Page 30 BRAKES (CAB) PUMP CIRCUIT FAILURE — Continued TEST ACTION APPLICABILITY Turn the ignition off. Disconnect the ABS Pump Motor connector. Check connectors - Clean/repair as necessary. Connect a 10 gauge 40 amp fused jumper wire between the ABS Pump Fused B(+) terminal in the CAB harness connector to the ABS Pump Motor connector RED wired terminal.
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Page 31: System Over Voltage
BRAKES (CAB) Symptom: SYSTEM OVER VOLTAGE When Monitored and Set Condition: SYSTEM OVER VOLTAGE When Monitored: Ignition on. The CAB monitors the Fused B(+) circuit at all times for proper system voltage. Set Condition: If the voltage is above 16.5 volts, the Diagnostic Trouble Code (DTC) is set. POSSIBLE CAUSES INTERMITTENT DTC BATTERY CHARGER CONNECTED... - Page 32 BRAKES (CAB) SYSTEM OVER VOLTAGE — Continued TEST ACTION APPLICABILITY Turn the ignition off. Disconnect the CAB connector. Note: Check connector - Clean/repair as necessary. Start the engine. Raise engine speed above 1,800 RPM’s Measure the voltage between Fused Ignition Switch Output (RUN) circuit and ground.
- Page 33 BRAKES (CAB) SYSTEM OVER VOLTAGE — Continued TEST ACTION APPLICABILITY 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.
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Page 34: System Under Voltage
BRAKES (CAB) Symptom: SYSTEM UNDER VOLTAGE When Monitored and Set Condition: SYSTEM UNDER VOLTAGE When Monitored: Ignition on. The CAB monitors the Fused Ignition Switch Output circuit voltage above 10 km/h (6 mph) continuously for proper system voltage. Set Condition: If the voltage is below 9.5 volts, the Diagnostic Trouble Code (DTC) is set. POSSIBLE CAUSES INTERMITTENT DTC DAMAGED CAB/CAB HARNESS CONNECTOR... - Page 35 BRAKES (CAB) SYSTEM UNDER VOLTAGE — Continued TEST ACTION APPLICABILITY Turn the ignition off. Disconnect the CAB harness connector. Inspect the CAB and CAB harness connector for damage. Is there any broken, bent, pushed out, corroded, or spread terminals? Yes → Repair as necessary. Perform ABS VERIFICATION TEST - VER 1.
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Page 36: Valve Power Feed Failure
BRAKES (CAB) Symptom: VALVE POWER FEED FAILURE When Monitored and Set Condition: VALVE POWER FEED FAILURE When Monitored: Ignition ON. The CAB monitors the Valve Fused B(+) circuit at all times for proper system voltage. Set Condition: If the Valve Fused B(+) is missing, the DTC will be set. POSSIBLE CAUSES INTERMITTENT DTC ABS VALVE FUSE... - Page 37 BRAKES (CAB) VALVE POWER FEED FAILURE — Continued TEST ACTION APPLICABILITY Turn the ignition off. Visually inspect the ABS Valve Fused B(+) circuit in the wiring harness. Look for any sign of an intermittent short to ground. Is the wiring harness OK? Yes →...
- Page 38 BRAKES (CAB) VALVE POWER FEED FAILURE — Continued TEST ACTION APPLICABILITY Reinstall the ABS Valve fuse. Disconnect the CAB harness connector. Using a 12-volt test light connected to ground, probe the ABS Valve Fused B(+) circuit at the CAB harness connector. Did the test light illuminate? Yes →...
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Page 39: Brake Lamp Switch Failure
BRAKES (CAB) Symptom: *BRAKE LAMP SWITCH FAILURE POSSIBLE CAUSES CHECK BRAKE LAMP SWITCH OUTPUT BRAKE LAMP SWITCH B+ OPEN BRAKE LAMP SWITCH OPEN BRAKE LAMP SWITCH OUTPUT CIRCUIT SHORT OR OPEN CAB -- INTERNAL OPEN TEST ACTION APPLICABILITY With the DRBIII in Inputs/Outputs, read the Brake Lamp Switch state. Press and release the brake pedal. -
Page 40: Communication
COMMUNICATION Symptom: *NO RESPONSE FROM CONTROLLER ANTILOCK BRAKE POSSIBLE CAUSES NO RESPONSE FROM CAB GROUND CIRCUIT OPEN OPEN FUSED IGNITION SWITCH OUTPUT CIRCUIT OPEN PCI BUS CIRCUIT CONTROLLER ANTILOCK BRAKE TEST ACTION APPLICABILITY Turn the ignition on. Note: As soon as one or more module communicates with the DRB, answer the question. - Page 41 COMMUNICATION *NO RESPONSE FROM CONTROLLER ANTILOCK BRAKE — Continued TEST ACTION APPLICABILITY Note: Ensure there is PCI Bus communication with other modules on the vehicle before proceeding. If not, refer to the symptom list from the menu and repair as necessary. Disconnect the CAB harness connector.
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Page 42: Verification Tests
VERIFICATION TESTS Verification Tests ABS VERIFICATION TEST - VER 1 APPLICABILITY 1. Turn the ignition off. 2. Connect all previously disconnected components and connectors. 3. Ensure all accessories are turned off and the battery is fully charged. 4. Ensure that the Ignition is on, and with the DRBIII, erase all Diagnostic Trouble Codes from ALL modules. -
Page 43: Component Locations
COMPONENT LOCATIONS 8.0 COMPONENT LOCATIONS 8.1 CONTROLLER ANTILOCK BRAKE, HYDRAULIC CONTROL UNIT, PUMP MOTOR 8.2 WHEEL SPEED SENSORS FRONT REAR... -
Page 44: Wheel Speed Sensor Connectors
COMPONENT LOCATIONS 8.3 WHEEL SPEED SENSOR CONNECTORS LEFT FRONT RIGHT FRONT 8.4 BRAKE LAMP SWITCH 8.5 BRAKE LAMP SWITCH CONNECTOR... -
Page 45: Connector Pinouts
CONNECTOR PINOUTS 9.0 CONNECTOR PINOUTS BRAKE LAMP SWITCH CIRCUIT FUNCTION F32 18PK/DB FUSED B(+) L50 18WT/TN (DIESEL) PRIMARY BRAKE SWITCH SIGNAL L50 18WT/TN (GAS) BRAKE LAMP SWITCH OUTPUT V30 18DB/RD SPEED CONTROL BRAKE SWITCH OUTPUT V32 18YL/RD SPEED CONTROL SUPPLY Z3 18BK/OR GROUND K29 18WT/PK (DIESEL) -
Page 46: Data Link Connector
CONNECTOR PINOUTS DATA LINK CONNECTOR CIRCUIT FUNCTION D25 18YL/VT PCI BUS Z252 18BK/GY GROUND Z252 18BK/GY GROUND D32 20LG/DG (GAS) SCI RECEIVE D32 20LG/DG (GAS) SCI RECEIVE D21 20PK/RD SCI TRANSMIT D24 18WT/DG FLASH ABS D19 20VT/OR BODY CONTROL MODULE FLASH ENABLE D20 20LG SCI RECEIVE F33 20PK/RD... -
Page 47: Rear Wheel Speed Sensor
CONNECTOR PINOUTS REAR WHEEL SPEED SENSOR CIRCUIT FUNCTION B2 18YL REAR WHEEL SPEED SENSOR 12 VOLT SUPPLY B1 18YL/DB REAR WHEEL SPEED SENSOR SIGNAL RIGHT FRONT WHEEL SPEED SENSOR (ABS) CIRCUIT FUNCTION B7 18WT RIGHT FRONT WHEEL SPEED SENSOR 12 VOLT SUPPLY B6 18WT/DB RIGHT FRONT WHEEL SPEED SENSOR SIGNAL... - Page 48 NOTES...
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Page 49: Schematic Diagrams
SCHEMATIC DIAGRAMS 10.0 SCHEMATIC DIAGRAMS TEVES MARK 20e CONTROLLER ANTILOCK BRAKE — ABS... - Page 50 NOTES...
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