Model 1431/40
Delco-Bosch ABS/TCS System Student Manual
Published by ATech Training, Inc. 12290 Chandler Drive Walton, KY 41094 USA
Phone: (859) 485-7229 Fax (859) 485-7299 Email:
[email protected] Website: www.atechtraining.com
Notice: General Motors Service Manual pages have been licensed to ATech for publication. All copyrights are still retained by ATech and General Motors. It is copyright infringement to copy those pages.
Delco-Bosch ABS/TCS System – 2008
Model 1431/40
Delco-Bosch ABS/TCS System NATEF TASKS Performance Objectives Upon completion of this ATech program you should be able to perform the following NATEF tasks.
V.
BRAKES G. Antilock Brake and Traction Control System
1.
Identify and inspect electronic brake control system components; determine necessary action.
P-1
3.
Diagnose electronic brake control system electronic control(s) and components by retrieving diagnostic trouble codes and/or using recommended test equipment; determine necessary action.
P-1
5.
Bleed the electronic brake control system hydraulic circuits.
P-1
6.
Remove and install electronic brake control system electrical/electronic and hydraulic components.
P-3
7.
Test, diagnose, and service electronic brake control system speed sensors (digital and analog), toothed ring (tone wheel), and circuits using a graphing multimeter (GMM)/digital storage oscilloscope (DSO) (includes output signal, resistance, shorts to voltage/ground, and frequency data).
P-1
9.
Identify traction control/vehicle stability control system components.
P-3
VI.
ELECTRICAL/ELECTRONIC SYSTEMS A. General Electrical System Diagnosis
2.
Identify and interpret electrical/electronic system concern; determine necessary action.
ATech Supports ASE/NATEF Delco-Bosch ABC/TCS System – 2008 1
P-1
6.
Use wiring diagrams during diagnosis of electrical circuit problems.
P-1
7.
Demonstrate the proper use of a digital multimeter (DMM) during diagnosis of electrical circuit problems, including: source voltage, voltage drop, current flow, and resistance.
P-1
9.
Check electrical/electronic circuit waveforms; interpret readings and determine needed repairs.
P-2
11.
Locate shorts, grounds, opens, and resistance problems in electrical/ electronic circuits; determine necessary action.
P-1
13.
Inspect and test fusible links, circuit breakers, and fuses; determine necessary action.
P-1
14.
Inspect and test switches, connectors, relays, solid state devices, and wires of electrical/electronic circuits; perform necessary action.
P-1
ATech Supports ASE/NATEF Delco-Bosch ABC/TCS System – 2008 2
DelcoBosch ABS/TCS System
Student Manual
Training Program The ATech Model 1431/40 Delco-Bosch ABS/TCS System Program is a series of student-paced activities that allow you to discover the operation, diagnosis, and service of the ABC/TSC System. ATech prides itself in never losing sight of our goal to provide you with well-organized, precise NEED TO KNOW information that will help you become a better automotive technician. Throughout these activities, you will be asked to take information and demonstrate your understanding of the material by completing worksheets, on-trainer exercises, and on-trainer diagnostics which can be linked directly to on-car service. NATEF Task Record Keeping: After you complete each section of the program, your instructor will record your progress on the NATEF Task Record Keeping Sheets.
Warning This program is designed to be a friendly, educational experience. Beware: Working with this program, you will learn skills that will help you on the job.
Delco-Bosch ABS/TCS System
Delco-Bosch ABS/TCS System
Model 1431/40
Delco-Bosch ABS/TCS System Program Outline I. INTRODUCTION 1. Program Overview • Student Manual • Bosch 5 Series ABS/TCS Reference Book • Service Manual Information • ABS/TCS Trainer Description • On-Trainer Worksheet II. ABS/TCS COMPONENT DESCRIPTION 2. Components • Component Introduction • Electronic Monitor and Control • Power Supply and Circuit Protection • Hydraulic System • Component Locations • On-Trainer Worksheet III. ABS/TCS OPERATION 3. Operation Part I • Basic Brake Operation • Knowledge Check Questions* • Non-ABS Operation • ABS Operation • On-Trainer Worksheet 4. Operation Part II • Electronic Brake Traction Control Module (EBTCM) • Wheel Speed Sensors • Knowledge Check Questions* • On-Trainer Worksheet
ATech Supports ASE/NATEF
Delco-Bosch ABS/TCS System
5. Operation Part III • Brake Switches • Service Manual Information • Solenoid Monitor Input • Throttle Position Sensor • TCS Off Switch • Knowledge Check Questions* • Accelerometers • EBTCM Output • On-Trainer Worksheet III. HYDRAULIC Operation 6. Hydraulic System Part I • Knowledge Check Questions* • Component Function • Non ABS Fluid Flow • Pressure Hold, Decrease, Increase • Engine Management • Knowledge Check Questions* • TCS Fluid Flow • On-Trainer Worksheet 7. Hydraulic System Part II • On-Trainer Worksheet • ABS Demonstration • Knowledge Check Questions* 8. Hydraulic System Part III • On-Trainer Worksheet • TCS Demonstration IV. STRATEGY BASED DIAGNOSTICS 9. Power On Self-Test • Auto-Test • Strategy Based Diagnostics • On-Trainer Worksheet 10. Continuous Self-Test • On-Trainer Worksheet V. SERVICE 11. • • •
On-Vehicle Safety Procedures Knowledge Check Questions* Component Locations
Delco-Bosch ABS/TCS System
*Note: Through out the training program, questions will be asked which are called Knowledge Check Questions. These questions check your knowledge of fundamental information that you should have acquired previously or your ability to apply mathematics, science, and writing skills. They will be identified by an asterisk (*) preceding the question number. If you do not know the answer to these questions, contact your instructor for assistance.
Delco-Bosch ABS/TCS System
Delco-Bosch ABS/TCS System
Delco-Bosch ABS/TCS System Student Manual
Delco-Bosch ABS/TCS System Activity 1 Program Overview Performance Objectives: The purpose of this activity is to understand the objectives of the Anti-Lock Brake/Traction Control System (ABS/TCS) training program and to provide an overview of the training materials. Tools and Materials: • ATech Model 1431/40 Delco-Bosch ABS/TCS System Trainer References: • Bosch 5 Series ABS/TCS Reference Book • Service Manual Information Locate the Following: • ATech Model 1431/40 Delco-Bosch ABS/TCS System Trainer • Student Manual (3 ring binder) • Bosch 5 Series ABS/TCS Reference Book During this program, you will be asked to work with one or more of these “pieces of equipment”.
Delco-Bosch ABS/TCS System – Activity 1
1-1
Student Manual: This ABS/TCS program is divided into separate learning activities. Each activity contains questions from either the Reference Book or Service Manual Information. Many of the activities also contain an On-Trainer Worksheet that requires the use of the ATech ABS/TCS Trainer. Bosch 5 Series ABS/TCS Reference Book: The Bosch 5 Series ABS/TCS Reference Book covers the Bosch 5, Delco-Bosch 5, and the Bosch 5.3 Systems. We will concentrate on the Delco-Bosch 5 System. Read Page 1-1 through 1-9 in the Reference Book to answer the following questions. 1. List the six sections of the Reference Book. a. b. c. d. e. f. 2. Define the following abbreviations. ABS EBTCM TCS 3. What is meant by ASR? 4. What is the difference between TCS and ASR? 5. During hard braking, wheel lockup is called “ 6. A wheel that is spinning has “
wheel slip” wheel slip”
7. What is Magnasteer? 8. The Bosch and Delco-Bosch Systems are non-integral, since the Assembly is not attached to the Master Cylinder for the base brake system.
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Delco-Bosch ABS/TCS System – Activity 1
9. List three benefits of ABS. a. b. c.
10. List three benefits of TCS. a. d. e.
Service Manual Information: 11. From the table of contents, what is the section that covers brakes? 12. From the detailed table of contents, what is the section that covers Anti-Lock Brake System (ABS) and Traction Control System (TCS)? 13. From page 5E2-5, what are the two reasons that the TCS Off Lamp may be lit? a. b. 14. From page 5E2-13, is the case of the Brake Pressure Modulator Valve Assembly grounded? 15. The brake switch input is connected to pin
of the EBTCM.
16. From the wiring diagram on page 5E2-14, the Right Rear Wheel Speed Sensor signal input is connected to pins and . 17. From page 5E2-20, a DTC 66 indicates what problem?
18. A DTC 21 indicates what problem?
Delco-Bosch ABS/TCS System – Activity 1
1-3
ABS/TCS Trainer Description: The ATech ABS/TCS Trainer displays an actual Delco-Bosch 5 ABS/TCS System as used on the 1996 Oldsmobile “88”. * Refer to the actual ATech ABS/TCS Trainer and/or the front panel illustration above to answer the following questions. Inputs: 19. How many sets of sensors and “toothed sensor rings” are there? Note: ATech uses the color Blue to indicate inputs to the ABS/TCS Electronic Controller. 20. What other input components are labeled in Blue?
1-4
Delco-Bosch ABS/TCS System – Activity 1
21. What component of the ABS/TCS System is the “decision maker”?
Outputs: Note: Outputs on ATech Trainers are indicated by the color Red. 22. The Brake Pressure Modulator Valve Assembly is one output device. What are the two other outputs on the Demonstrator? a. b. Demonstrator Controls: Locate the following components on the left-hand side of the board: Wheel Select Knob Conditions Knob TCS Operation/ABS Operation Switch ABS System “Active/Inactive” Switch The Wheel Select Knob selects the wheel that will lockup for ABS or spin for TCS. The Road Conditions Knob will select the type of road surface conditions the ABS/TCS System is operating on. This allows comparison of stopping/starting distances for the four road surfaces, Ice, Snow, Wet, and Dry. The TCS Operation/ABS Operation Switch permits selection of which type of function to demonstrate on the trainer, Traction Control or Anti-Lock Brakes.
The ABS System Active/Inactive Switch allows the ABS System to be disabled to permit the student to see stopping action without the aid of ABS.
Note: The TCS On/Off Switch (located below the trainer controls panel) is not a Demonstrator Control. It is a System Control Switch which allows the driver to turn the Traction Control
System on or off in the vehicle. Some vehicles using this Delco-Bosch 5 System have this switch while others do not.
Delco-Bosch ABS/TCS System – Activity 1
1-5
Another Demonstrator Control is located in the Brake Pressure Modulator Valve area. It is the EBTCM/BPMV Connect-Disconnect Switch. This switch gives the same effect as separating the EBTCM from the BPMV as required in some diagnostic steps. The tip jacks allow measurements within the BPMV.
The Sensor Harness Disconnect Switches are trainer controls that disconnect the Wheel Speed Sensors from their respective harnesses to allow sensor and harness measurements.
1.6
Delco- Bosch ABS/TCS System- Activity 1
• Locate the following Displays:
Vehicle Speed (MPH)
Starting/Stopping Distance
Delco- Bosch ABS/TCS System – Activity 1
1-7
Skid Indicator
Torque Request/Magnasteer
Conclusion: The ATech ABS/TCS Trainer can be used to observe the actual operation of a Four Wheel ABS/TCS System including solenoid control and system monitoring by the Electronic Controller. Also ABS/TCS test procedures and diagnostic procedures can be practiced as they would be performed on a live vehicle.
Complete the On-Trainer Worksheet at this time.
1.8
Delco- Bosch ABS/TCS System – Activity 1
ON-TRAINER WORKSHEET Activity 1 Set-Up: Before operating the ATech Trainer, perform the following Set-Up Procedure. • Make sure the Four Wheel Sensor/Harness Switches on each side of the vehicle are in the Connect position. • Make sure the EBTCM/BPMV Switch is in the Connect position. ABS Demonstration: • Set the Wheel Select Knob to LF (left front). • Set the Road Conditions Switch to Dry. • Set the ABS System Switch to Active. • Set the TCS Operation - ABS Operation Switch to ABS Operation. • Locate the “Power Block” in the lower right-hand corner of the ABS/TCS Board and identify the following: a. System Power Switch and LED Indicator b. Battery Probe Point (POS) c. System Ground d. Fuse Block • Turn System Power ON. • Locate the following components in the bottom left-hand side of the board: a. Ignition Switch b. Gas Pedal c. Brake Pedal • Turn the Ignition Switch ON (clockwise). Note: A “zero” should be displayed on the vehicle Speed and Starting/Stopping Distance displays. ATech’s logo should appear on the Skid Indicator Display. • Press the Gas Pedal and accelerate to 30 MPH. • Get a “feel” for the Gas Pedal by trying to maintain 30 MPH. Note: The Traction Control System may operate the solenoids on wheel start-up due to the very slight difference in wheel start times and speeds on the trainer. This can be prevented by turning the TCS Off with the TCS On/Off Switch. 1. Describe the motion of the wheels.
Delco- Bosch ABS/TCS System – Activity 1
1-9
Release the Gas Pedal. Apply the Brake Pedal - ALL THE WAY until the vehicle stops. 2. According to the Starting/Stopping Distance Display, how many feet did it take to stop? Stopping Distance Without ABS: The trainer allows the student to compete against the ABS System in stopping the vehicle. After you accelerate, stop the vehicle by applying the brake. Watch the Skid Indicator for excessive braking as you stop the vehicle. If you apply too much brake, the vehicle will start to skid off the road as shown on the LCD Display. If you crash, no distance will be displayed. You can accelerate and try again. Set the ABS System Active/Inactive Switch to Inactive. Accelerate to 30 MPH. Brake the vehicle to a stop as rapidly as possible without crashing. Try this a few times and record your best stopping distance. The ABS System can be beat but it takes almost perfect braking action. Turn the Ignition Switch OFF. TCS Demonstration: The TCS Demonstration Mode on the trainer allows the student to accelerate to approximately 30MPH. The distance that is required to reach 30MPH is recorded. • Set the Wheel Select Knob to LF (left front). • Set the Road Conditions Switch to Dry. • Set the ABS System Switch to Inactive. • Set the TCS Operation - ABS Operation Switch to TCS Operation. • Turn the Ignition Switch ON. Note: A “zero” should be displayed on the vehicle Speed and Starting/Stopping Distance Displays. ATech’s logo should appear on the Skid Indicator Display. • Press the Gas Pedal all the way down (wide open throttle).
1-10
Delco-Bosch ABS/TCS System – Activity 1
3. According to the Starting/Stopping Distance Display, how many feet did it take to reach 30 MPH? Release the Gas Pedal and press the Brake Pedal to return to 0 MPH. Starting Distance without TCS: The trainer allows the student to compete against the TCS System in accelerating the vehicle to 30 MPH. As you accelerate, watch the Skid Indicator for excessive acceleration. If you accelerate too rapidly, the vehicle will start to skid off the road as shown on the LCD Display. If you crash, no distance will be displayed. If you accelerate and reach 30 MPH without crashing but the distance is greater than the TCS value, you can brake and try again. Press the TCS System On/Off Switch to turn ON the TCS Off Light. Accelerate to 30 MPH as rapidly as possible without crashing. Try this a few times and record your best starting distance. The TCS System can be beat but it takes almost perfect acceleration. Turn the Ignition Switch OFF. Turn the System Power OFF.
Delco-Bosch ABS/TCS System – Activity 1
1-11
1.12
Delco-Bosch ABS/TCS System – Activity 1
Delco-Bosch ABS/TCS System Student Manual
Delco-Bosch ABS/TCS System Activity 2 Components Performance Objectives: The purpose of this activity is to gain a familiarity with the component parts of the ABS/TCS System as to their location and purpose. Tools and Materials: ATech Model 1431/40 Delco-Bosch ABS/TCS System Trainer References: Bosch 5 Series ABS/TCS Reference Book
Delco-Bosch ABS/TCS System – Activity 2
2-1
Read chapter 2 in the Reference Book and use the information to answer the following questions. Overview: 1. List the three functions of the components of the system. a. b. c. Components Introduction: 2. Identify the components in the following figure.
Electronic Monitor and Control: 3. Signals that come from each wheel that represent the wheel’s rotational speed are generated by the . 4. One input to the EBTCM is the the Powertrain Control Module (PCM).
Signal from
5. List the four solenoids that are outputs from the EBTCM. a. b. c. d. Power Supply and Circuit Protection: 6. From Figure 2-12, what is the size of the fuse for ignition power to EBCM or EBTCM?
2-2
Delco-Bosch ABS/TCS System – Activity 2
Hydraulic System: 7. Identify the components in the following figure.
Delco-Bosch ABS/TCS System – Activity 2
2-3
Component Locations: 8. Identify the Rear Axle Speed Sensor in the following figure.
9. Identify the Front Wheel Speed Sensor in the following figure.
Conclusion: Components of the ABS/TCS System are located throughout the vehicle. Location and type of component vary depending on the body model being serviced. Complete the On-Trainer Worksheet at this time.
2-4
Delco-Bosch ABS/TCS System – Activity 2
ON-TRAINER WORKSHEET Activity 2
Locate and identify in the above figure the following listed items: • RF Prime Solenoid • LF Sensor • Pump Motor • Torque Request Indicator • Wheel Select Switch • Magnasteer Indicator • Road Conditions Select Switch • EBTCM • ABS System Active/Inactive Switch • Ignition Switch • Speedometer • RR Hold Solenoid • Gas Pedal • TCS Active Indicator • Brake Pedal • RR Release Solenoid • Starting/Stopping Distance Readout
Delco Bosch ABS/TCS System – Activity 2
2-5
2.6
Delco-Bosch ABS/TCS System – Activity 2
Delco-Bosch ABS/TCS System Student Manual
Delco-Bosch ABS/TCS System Activity 3 Operation Part I Performance Objectives: The purpose of this activity is to study and observe the operation of the Anti-Lock Brake and Traction Control Systems. Tools and Materials: • ATech Model 1431/40 Delco-Bosch ABS/TCS System Trainer • Scan Tool (one of the following) ➢ Tech 1 with GM Chassis Cartridge and suitable adapters for J 1962 Connector ➢ OTC Monitor 4000 enhanced with ABS 98 Cartridge, 3305-73 System Smart Cable, and 3306-03 or 3306-07 GM System Smart 25 pin Insert References: • Bosch 5 Series ABS/TCS Reference Book
Delco-Bosch ABS/TCS System – Activity 3
3-1
Read page 3-2 in the Reference Book and answer the following questions. Basic Brake Operation: 1. The Master Cylinder Front Outlet connects through the BPMV to the and
Wheel Cylinders.
2. The Rear Outlet of the Master Cylinder connects through the BPMV to the and
Wheel Cylinders.
Note: Through out the training program, questions will be asked which are called Knowledge Check Questions. These questions check your knowledge of fundamental information that you should have acquired previously. They will be identified by an asterisk (*) preceding the question number. If you do not know the answer to these questions, contact your instructor for assistance. Knowledge Check Questions*: *3. Why are standard vehicle brake systems configured as Dual or Split Systems?
*4. Why are the Split Brake Systems connected to control diagonally opposite wheels? Example: Left Front and Right Rear.
*5. What is the purpose of the proportioning valve placed in the brake lines going to the rear wheels in most vehicles?
Read page 3-8 in the Reference Book and answer the following questions. Non-ABS Operation: 6. During Non-ABS Braking, the Hold Valve Solenoid is electrically hydraulically . 7. During Non-ABS Braking, the Release Valve Solenoid is electrically hydraulically .
and
and
3-2
Delco-Bosch ABS/TCS System – Activity 3
ABS Operation: 8. During Pressure Hold Mode, the Hold Valve Solenoid is electrically hydraulically .
and
9. During Pressure Hold Mode, the Release Valve Solenoid is electrically hydraulically .
and
10. During Pressure Decrease Mode, the hold Valve Solenoid is electrically hydraulically .
and
11. During Pressure Decrease Mode, the Release Valve Solenoid is electrically hydraulically .
and
12. During Pressure Increase Mode, the Hold Valve Solenoid is electrically hydraulically .
and
13. During Pressure Increase Mode, the Release Valve Solenoid is electrically hydraulically .
and
14. In Traction Control Mode of operation, if the EBTCM detects positive wheel slip during acceleration, it sends a signal to the PCM through the circuit. 15. The PCM will engine spark timing in response to the signal in question 14 and send a signal to the EBTCM through the circuit. 16. At speeds above 45 MPH, the electromagnetic force of the Magnasteer Actuator causes the control valve to provide steering effort and better road feel for the driver. Conclusion: The three modes of operation for the ABS/TCS System are Pressure Hold, Pressure Decrease, and Pressure Increase. During TCS Operation, as wheels slip, requests for reduced torque are sent to the PCM. The PCM will reduce Spark Advance to reduce the torque applied to the wheels. Magnasteer increases steering effort at higher vehicle speed for better road feel. Complete the On-Trainer Worksheet at this time.
Delco-Bosch ABS/TCS System – Activity 3
3-3
3.4
Delco-Bosch ABS/TCS System – Activity 3
ON-TRAINER WORKSHEET Activity 3 Set-Up: Before operating the ATech Trainer, perform the following Set-Up Procedure. Make sure the Four Wheel Sensor/Harness Switches on each side of the vehicle are in the Connect position. Make sure the EBTCM/BPMV Switch is in the Connect position. TCS Demonstration: Torque Request Set the Wheel Select Knob to LF (left front). Set the Road Conditions Switch to Ice. Set the ABS System Switch to Inactive. Set the TCS Operation - ABS Operation Switch to TCS Operation. Locate the “Power Block” in the lower right-hand corner of the ABS/TCS Board and turn System Power ON. Turn the Ignition Switch ON. Note: A “zero” should be displayed on the vehicle Speed and Starting/Stopping Distance Displays. ATech’s logo should appear on the Skid Indicator Display. Locate the Torque Request bar graph. 1. What request is displayed? Locate the Magnasteer bar graph. 2. What steering effort is indicated? Press the Gas Pedal all the way down and observe the action of the Torque Request bar graph. 3. Describe the action of the Torque Request bar graph.
4. What does this action indicate to the PCM?
Using the Brake Pedal, decelerate the vehicle to 0 MPH.
Delco-Bosch ABS/TCS System – Activity 3
3-5
Magnasteer: Set the ABS System Switch to Active. Set the TCS Operation - ABS Operation Switch to ABS Operation. Press the Gas Pedal all the way down and observe the Magnasteer Indicator until the vehicle speed goes over 70 MPH, release the Gas Pedal and observe the Indicator as the speed decreases to 0 MPH. 5. Describe your observation.
Turn the Ignition Switch and System Power OFF.
3.6
Delco-Bosch ABS/TCS System – Activity 3
Delco-Bosch ABS/TCS System Student Manual
Delco-Bosch ABS/TCS System Activity 4 Operation Part II Performance Objectives: The purpose of this activity is to continue the study and observation of the operation of the Anti-Lock Brake and Traction Control Systems. Tools and Materials: • ATech Model 1431/40 Delco-Bosch ABS/TCS Trainer • Meter for measuring Volts and Ohms • Scan Tool (one of the following) ➢Tech 1 with GM Chassis Cartridge and suitable adapters for J1962 Connector ➢OTC Monitor 4000 enhanced with ABS 98 Cartridge, 3305-73 System Smart Cable, and 3306-03 or 3306-07 GM System Smart 25 Pin Insert • Oscilloscope References: • Bosch 5 Series ABS/TCS Reference Book • Service Manual Information
Delco-Bosch ABS/TCS System – Activity 4
4-1
Electronic Brake Traction Control Module (EBTCM): • Read pages 3-10 and 3-11 in the Reference Book and answer the following questions. 1. List the EBTCM primary functions. a. b. c. d. e. f.
4-2
Delco-Bosch ABS/TCS System – Activity 4
2. Fill in the empty blanks with the correct answers in the following diagram.
Delco-Bosch ABS/TCS System – Activity 4
4-3
Read page 3-12 in the Reference Book and answer the following questions. 3. A vehicle Start-Up Check is performed on which of the following components of the EBTCM System? Brake Cylinders EBTCM Circuits Brake Hydraulic Lines Lateral Accelerometer
Battery Voltage Master Cylinder Wheel Speed Sensor Circuits Reservoir Fluid Level Switch
4. A Vehicle In-Motion Check is performed when the vehicle reaches approximately MPH. Note: The ABS/TCS Trainer accelerates rapidly to approximately 9 MPH when the Gas Pedal is pushed. All wheels on the unit do not start at exactly the same time therefore the TCS System will typically activate upon pushing the Gas Pedal. The Vehicle In-Motion Check will typically be obscured by the TCS activation upon pushing the Gas Pedal. 5. What vehicle body models have Throttle Close-Down capability? Read pages 3-14 and 3-15 in the Reference Book and answer the following questions. Wheel Speed Sensors: 6. What is the primary purpose of the Wheel Speed Sensors?
Knowledge Check Questions*: You should have previously acquired the math skills to answer the following Applied Mathematics Questions. *7. If a Wheel Speed Sensor has 60 equally spaced teeth and rotates at 50 revolutions per minute, what is the time of one AC cycle produced by one tooth and gap interval?
*8. What is the frequency of the cycle produced in question 7? *9. If a vehicle has a wheel with a diameter of 26.738 inches, what is the circumference of the wheel? (hint: C = pi x diameter)
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Delco-Bosch ABS/TCS System – Activity 4
*10. If a Wheel Speed Sensor having 60 teeth is attached to the wheel in question 9 and one AC cycle time from the sensor is .002 seconds, what is the vehicle speed in MPH?
Applied Science Question: *11. Illustrate the magnetic field around the bar magnet in the following figure.
12. The factory sets the air gap between the toothed sensor ring and sensor. This gap is not adjustable. Note: The ATech ABS/TCS Trainer uses generic toothed sensor rings and sensors. They can be adjusted on the trainer. The sensors in the vehicle are not adjustable. 13. ABS/TCS Speed Sensor Circuit wiring is extremely sensitive to interference. Conclusion: The Wheel Speed Sensors are magnetic pickup devices that generate an AC Signal as the toothed ring rotates. The teeth interrupt the magnetic field causing it to change. As the field changes it passes through the sensor’s internal coil of wire inducing a voltage which is monitored by the EBTCM. Complete the On-Trainer Worksheet at this time.
Delco-Bosch ABS/TCS System – Activity 4
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4.6
Delco-Bosch ABS/TCS System – Activity 4
ON-TRAINER WORKSHEET Activity 4 Set-Up: Before operating the ATech Trainer, perform the following Set-Up Procedure. • Make sure the Four Wheel Sensor/Harness Switches on each side of the vehicle are in the Connect position. • Make sure the EBTCM/BPMV Switch is in the Connect position. • Set the Wheel Select Knob to LF (left front). • Set the Road Conditions Switch to Ice. • Set the ABS System Switch to Inactive. • Set the TCS Operation - ABS Operation Switch to ABS Operation. • Locate the “Power Block” in the lower right-hand corner of the ABS/TCS Board and turn System Power ON. • Make sure the Ignition Switch is OFF. • Using the Sensor/Harness Disconnect Switches, disconnect each of the sensors from their harnesses. 1. Measure and record below the value of each sensor’s resistance. LF
RF
LR
RR
• Go to page 5E2-55 and Step 8 in the Service Manual Information. 2. What is the resistance value expected for a Wheel Sensor? 3. Are your measured values from the trainer okay? • Reconnect all of the Wheel Speed Sensors to their harnesses by setting the switches to the Connect position. • Connect your Scan Tool and turn the Ignition Switch ON. 4. Read out the DTCs with the Scan Tool and list below. 5. Disconnect the Left Front Wheel Sensor using the Harness Disconnect Switch and describe what happens.
Delco-Bosch ABS/TCS System – Activity 4
4-7
6. What is the DTC shown on the Scan Tool? Go to page 5E2-20 in the Service Manual Information. 7. What does this DTC mean? 8. What page is given for the diagnostic procedure? Set the Harness Disconnect Switch for the LF Wheel Sensor to Connect position. 9. Read the DTCs with the Scan Tool. Is the Fault Code still present? Turn the Ignition Switch OFF and then ON. 10. Read the DTCs with the Scan Tool. Is the Fault Code still present? Set your voltmeter to read DC Volts. 11. What is the DC Voltage at each sensor? LF
RF
LR
RR
12. Accelerate to 50 MPH and measure the DC Voltage at each sensor again. LF
RF
LR
RR
Use the Brake to return the Vehicle Speed to 0 MPH. 13. Set your meter for AC Voltage measurement and measure each Wheel Sensor. LF
RF
LR
RR
14. Measure the AC Voltage generated by each sensor at each of the following vehicle speeds. 15 30 45 60 LF RF LR RR Instructor Note: These values can vary widely depending on spacing of the sensors. Values for a particular sensor should increase as speed increases.
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Delco-Bosch ABS/TCS System – Activity 4
15. Which sensor has the smallest AC Output at 60 MPH? 16. Which sensor has the largest AC Output at 60 MPH? Observe the gap between sensor and toothed ring for the two sensors you listed. 17. What relationship can you determine?
Connect an oscilloscope to measure the signal from the RF Wheel Speed Sensor. Accelerate the vehicle to 20 MPH and measure and record the time for one cycle of the signal. 18. What is the time for one cycle of the signal? Applied Mathematics Question: *19. Using a reverse process from the earlier math questions, using 50 teeth on the ring, 20 MPH and the time you measured in question 18, you should be able to calculate the diameter of the vehicle’s wheel.
Applied Electrical Question: *20. How does the EBTCM know when the sensor is disconnected if the wheels are not rotating?
Delco-Bosch ABS/TCS System - Activity 4
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Delco-Bosch ABS/TCS System – Activity 4
Delco-Bosch ABS/T System
Student Manual
Delco-Bosch ABS/TCS System Activity 5 Operation Part III Performance Objectives: The purpose of this activity is to continue the study and observation of the operation of the Anti-Lock Brake and Traction Control Systems. Tools and Materials: • ATech Model 1431-40 Delco-Bosch ABS/TCS System Trainer • Scan Tool (one of the following) ➢Tech 1 with GM Chassis Cartridge and suitable adapters for J1962 Connector ➢OTC Monitor 4000 enhanced with ABS 98 Cartridge, 3305-73 System Smart Cable, and 3306-03 or 3306-07 GM System Smart 25 Pin Insert References: • Bosch 5 Series ABS/TCS Reference Book • Service Manual Information
Delco Bosch ABS/TCS System Trainer – Activity 5
5-1
Read pages 3-16 through 3-18 in the Reference Book and answer the following questions. Brake Switches: 1. The EBTCM will not initiate ABS Operation until it receives a signal for the switch. 2. When the driver presses the Brake Pedal, current flows to the Brake Lights and to the . Note: The Bosch 5 System has another Brake Input Switch which is normally closed and opens when the Brake Pedal is depressed approximately 40%. It is referred to as the Brake Extended Travel Switch or the TCS/Anti-Lock Brake Switch. Service Manual Information: Go to the schematic on page 5E2-13 in the Service Manual Information. 3. What pin on the EBTCM connects to the Extended Brake Travel Switch? Solenoid Monitor Input: 4. The EBTCM checks for a signal from the solenoid relay input during:
Throttle Position Sensor: 5. What does the abbreviation TAC mean? 6. What is the purpose of TAC?
TCS Off Switch: 7. Pressing the TCS Off Switch
the Traction Control System on and off.
8. When the TCS Off Lamp is not illuminated, is the TCS System on or off?
5-2
Delco-Bosch ABS/TCS System - Activity 5
Knowledge Check Questions*: You should have previously acquired the Science Knowledge to answer the following Applied Science Questions. *9. Define “Acceleration”.
*10. What is meant by “G-Force”?
Accelerometers: 11. The lateral G-Force generated during accelerometer.
is measured by the lateral
12. Stabilitrak is a GM System to improve the cornering ability of a vehicle. List the three inputs that the Stabilitrak System monitors. a. b. c. Read pages 3-19 through 3-22 in the Reference Book and answer the following questions. EBTCM Output: 13. The EBTCM energizes the solenoid relay whenever:
14. The Brake Pressure Modulator Valve can brake fluid pressure.
,
15. The Modulator Valve can/can not provide more pressure than is applied by the Master Cylinder. (Circle correct answer) 16. The three phases that can be produced at each wheel during ABS action are: a. b. c.
, or
Delco-Bosch ABS/TCS System – Activity 5
5-3
17. What is the purpose of the Prime Valves?
18. The solenoid power relay and serviced as part of the EBCM or EBTCM. 19. The
power relay are
may be services as a separate part of the complete assembly.
20. The motor is services as part of the
.
Conclusion: Two brake switches supply input to the EBTCM. They are the Brake Light Switch and the Extended Brake Travel Switch. The EBTCM monitors activation of the brakes during both ABS and TCS activity and estimates the brake rotor temperature. If the temperature exceeds a certain value, the EBTCM will disable the TCS System until it estimates that the temperature has reduced to a safe value. Complete the On-Trainer Worksheet at this time.
5.4
Delco-Bosch ABS/TCS System - Activity 5
ON-TRAINER WORKSHEET Activity 5 Set-Up: Before operating the ATech Trainer, perform the following Set-Up Procedure. • Make sure the Four Wheel Sensor/Harness Switches on each side of the vehicle are in the Connect position. • Make sure the EBTCM/BPMV Switch is in the Connect position • Set the Wheel Select Knob to LF (left front). • Set the Road Conditions Switch to Ice. • Set the ABS System Switch to Active. • Set the TCS Operation - ABS Operation Switch to ABS Operation. • Locate the “Power Block” in the lower right-hand corner of the ABS/TCS Board and turn System Power ON. • Connect your Scan tool and initialize. • Turn Ignition Switch ON. • Set the Scan Tool to display both the Brake Switch and the Brake Extended Travel Switch. 1. Does the Scan Tool show both of them to be Released (off) or Applied (on)?
2. Press the Brake Pedal only far enough to light the brake lights on the trainer. Record the status of the two switches below. Brake Switch Brake Travel Switch 3. Press the Brake Pedal down until the Brake Travel Switch on the Scan Tool indicates applied. Does this occur at about 40% travel? • Set the Scan Tool to display Fault Codes. Accelerate the trainer to reach its maximum speed and release the Gas Pedal. Press the Brake Pedal completely down and observe the Solenoid Indicator Lights as the ABS works. 4. Which Solenoid Indicator Lights illuminate?
Delco-Bosch ABS/TCS System - Activity 5
5-5
5. Which Solenoid Indicator Light stops illuminating below 20 MPH? When the vehicle speed equals 0 MPH, release the Brake Pedal, and turn the Ignition Switch OFF. Wait one minute and turn the Ignition Switch ON. After the initial Diagnostic Self Test. Check the TCS Off Light. It should be OFF (not lit) indicating that the TCS System is Active. Accelerate the trainer to reach its maximum speed and release the Gas Pedal. Press the Brake Pedal completely down and bring the trainer to a complete stop (vehicle speed = 0). Press the accelerator to reach 5 MPH. Note the time. 6. What happened to the TCS Off Light? 7. When the light is on, what does this indicate?
8. What DTC is indicated on the Scan Tool? 9. Monitor the time and measure how long the TCS Off Light is ON. Note: If the TCS Off Light is not lit, the TCS System is operational but the Fault Code from the previous steps will be present until the ignition is cycled. Turn the Ignition Switch OFF. Wait 30 seconds and turn the Ignition Switch ON. 10. Using the Scan Tool, read the Fault Codes again. What code is indicated? 11. From page 5E2-20, a DTC 38 indicates what problem?
12. What page is indicated for the diagnostic procedure? 13. At what brake rotor temperature does DTC 38 set? 14. If the TCS System turns the TCS Off Light on of excessive rotor temperature, as the rotors cool down, at what brake rotor temperature will the TCS System turn the TCS Off Light off?
15. How does the EBTCM know the temperature of the brake rotors?
Turn the Ignition Switch and the System Power OFF.
5-6
Delco-Bosch ABS/TCS System- Activity 5
Delco-Bosch ABS/T System
Student Manual
Delco-Bosch ABS/TCS System Activity 6 Hydraulic System Part I Performance Objectives: The purpose of this activity is to study the hydraulic operation of the Anti-Lock Brake and Traction Control Systems. Tools and Materials: • ATech Model 1431/40 Delco-Bosch ABS/TCS Trainer References: • Bosch 5 Series ABS/TCS Reference Book
Delco-Bosch ABS/TCS System – Activity 6
6-1
Knowledge Check Questions*: *1. What is the purpose of the “Check Valve”? *2. In the following figure, circle each Check Valve.
DIAGONAL SPLIT
6-2
Delco-Bosch ABS/TCS System – Activity 6
Read pages 3-23 through 3-37 in the Reference Book for the following questions. Component Function: 3. What are the two purposes of the Recirculation Pump in the BPMV? a. b.
4. What is the purpose of the Brake Fluid Accumulators?
5. The Bosch 5 Series BPM has one normally Inlet and one normally Outlet Solenoid Valve for each wheel. 6. The two TCS Solenoid Valves are isolation and prime. What is the purpose of the Isolation Valve?
7. What is the purpose of the TCS Prime Solenoid Valve?
8. List the hydraulic control components of the BPMV. Note: Use the Diagonally Split system shown in Figure 3-21. It is not the same as the list of components at the top of page 3-25.
9. In figure 3-21, a Solenoid Valve is shown as a normally Closed Valve when it should be a normally Open Valve. Which valve is incorrect?
Delco-Bosch ABS/TCS System – Activity 6
6-3
Non-ABS Fluid Flow: 10. In the following figure, show the normal braking (Non-ABS) fluid flow.
DIAGONAL SPLIT
6-4
Delco-Bosch ABS/TCS System – Activity 6
11. If a Wheel Speed Sensor indicates excessive deceleration during braking, the EBTCM will:
12. Closing an Inlet Valve prevents additional from entering the circuit and maintains the established brake pressure in the caliper. 13. The action described in question 12 is called: (circle the correct answer) a. Pressure Increase b. Pressure Decrease c. Pressure Hold 14. If the wheel continues to decelerate too rapidly, the EBTCM will:
15. Opening an Outlet Valve and reduces brake pressure.
brake fluid from the caliper
Pressure Hold, Decrease, Increase: 16. The action described in question 15 is called: (circle the correct answer) a. Pressure Increase b. Pressure Decrease c. Pressure Hold 17. Once the Wheel Speed Sensor indicates no impending lockup, the EBTCM closes the Outlet Valve and reopens the Inlet Valve allowing pressure to increase. This action is called: (circle the correct answer) a. Pressure Increase b. Pressure Decrease c. Pressure Hold
Delco-Bosch ABS/TCS System – Activity 6
6-5
18. In the circuit below, indicate the LR Hold Solenoid. 19. If the LF Wheel was in the Pressure Release Mode, indicate which solenoid would be Closed and which would be Open.
DIAGONAL SPLIT
6.6
Delco-Bosch ABS/TCS System – Activity 6
Engine Management: 20. List the three possible Engine Management and brake intervention strategies that may be used during Traction Control. a. b. c.
21. TCS induced Spark Retard
decrease timing beyond Top Dead Center (TDC).
Knowledge Check Questions*: *22. How does retarding the spark advance reduce engine output torque?
*23. What is meant by Top Dead Center (TDC)?
TCS Fluid Flow: When TCS Brake Intervention is required, the Isolation Solenoid Valve is turned on (closed) to prevent fluid from the pump going to the Master Cylinder. The fluid is allowed to flow to the controlled brake caliper. The Prime Solenoid Valve is turned on (open) for two purposes: ➢ To provide a path for fluid flow to the pump from the reservoir. ➢ To provide a path for fluid flow to relieve pressure if the EBTCM activates the Release Solenoid during the TCS event.
Delco-Bosch ABS/TCS System – Activity 6
6-7
24. In the following figure, illustrate fluid flow for a TCS Activation of the Left Front Circuit.
DIAGONAL SPLIT Conclusion: The EBTCM controls various solenoids to prevent positive and negative wheel slippage. Whether wheels are controlled individually or together is determined by the original system engineers based upon vehicle characteristics and safety concerns. Complete the On-Trainer Worksheet at this time.
6.8
Delco-Bosch ABS/TCS System – Activity 6
ON-TRAINER WORKSHEET Activity 6 Set-Up: Before operating the ATech Trainer, perform the following Set-Up Procedure. • Make sure the Four Wheel Sensor/Harness Switches on each side of the vehicle are in the Connect position. • Make sure the EBTCM/BPMV Switch is in the Connect position. • Set the Wheel Select Knob to LF (left front). • Set the Road Conditions Switch to Ice. • Set the ABS Systems Switch to Active. • Set the TCS Operation - ABS Operation Switch to ABS Operation. • Locate the “Power Block” in the lower right-hand corner of the ABS/TCS Board and turn System Power ON. • Connect your Scan Tool and initialize. • Turn Ignition Switch ON. • Accelerate to 45 MPH and then apply full braking force. 1. List the “Hold” Hydraulic Solenoid Control Valves which are activated as the vehicle stops.
2. Which “Hold” Hydraulic Solenoid Control Valve is not activated by the EBTCM below approximately 20 MPH?
3. List the “Release” Hydraulic Solenoid Control Valve that is activated as the vehicle stops.
Note: After the vehicle has stopped and the Brake Pedal is released, the two Prime Solenoids are activated. This allows any residual pressurized fluid in the hydraulic circuit to be returned to the reservoir as a safety precaution.
Delco-Bosch ABS/TCS System – Activity 6
6-9
Turn the Ignition Switch OFF, wait 10 seconds and turn the Ignition Switch ON. Set the Wheel Select to RF. Accelerate to 45 MPH and then apply full braking force. 4. List the “Hold” Hydraulic Solenoid Control Valves which are activated as the vehicle stops.
5. List the “Release” Hydraulic Solenoid Control Valve that is activated as the vehicle stops.
6. Which “Hold” Hydraulic Solenoid Control Valve is not activated by the EBTCM below approximately 20 MPH?
Turn the Ignition Switch OFF, wait 10 seconds and turn the Ignition Switch ON. Set the Wheel Select to LR. Accelerate to 45 MPH and then apply full braking force. 7. List the “Hold” Hydraulic Solenoid Control Valves which are activated as the vehicle stops.
8. List the “Release” Hydraulic Solenoid Control Valves which are activated as the vehicle stops.
6-10
Delco-Bosch ABS/TCS System – Activity 6
9. Which “Hold” Hydraulic Solenoid Control Valves are not activated by the EBTCM below approximately 20 MPH?
Turn the Ignition Switch OFF, wait 10 seconds and turn the Ignition Switch ON. Set the Wheel Select to RR. Accelerate to 45 MPH and then apply full braking force. 10. List the “Hold” Hydraulic Solenoid Control Valves which are activated as the vehicle stops.
11. List the “Release” Hydraulic Solenoid Control Valves which are activated as the vehicle stops.
12. Which “Hold” Hydraulic Solenoid Control Valves are not activated by the EBTCM below approximately 20 MPH?
Note: The rear wheels are operated together on this system the same as a three way system. Turn the Ignition Switch and the System Power OFF.
Delco-Bosch ABS/TCS System – Activity 6
6-11
6-12
Delco-Bosch ABS/TCS System – Activity 6
Delco-Bosch ABS/TCS System Student Manual
Delco-Bosch ABS/TCS System Activity 7 Hydraulic System Part II Performance Objectives: The purpose of this activity is to study and observe the operation of the Anti-Lock Brake System. Tools and Materials: • ATech Model 1431-40 Delco-Bosch ABS/TCS System Trainer References: • None
Delco-Bosch ABS/TCS System – Activity 7
7-1
7.2
Delco-Bosch ABS/TCS System – Activity 7
On-Trainer Worksheet Activity 7 Set-Up: Before operating the ATech Trainer, perform the following Set-Up Procedure. • Make sure the Four Wheel Sensor/Harness Switches on each side of the vehicle are in the Connect position. • Make sure the EBTCM/BPMV Switch is in the Connect position. • Set the Wheel Select Knob to LF (left front). • Set the Road Conditions Switch to Ice. • Set the ABS System Switch to Active. • Set the TCS Operation - ABS Operation Switch to ABS Operation. • Locate the “Power Block” in the lower right-hand corner of the ABS/TCS Board and turn System Power ON. • Turn Ignition Switch ON. Note: If DTC 38 sets during the following activities and the TCS Off Light illuminates, it does not affect the results of the activities. • Accelerate to 50 MPH. • Apply full braking force. 1. Record the stopping distance required to stop a vehicle traveling on ice at 50 MPH.
• Set the Road Condition to Snow. • Accelerate to 50 MPH. • Apply full braking force. 2. Record the stopping distance required to stop a vehicle traveling on snow at 50 MPH.
Set the Road Condition to Wet. Accelerate to 50 MPH. Apply full braking force.
Delco-Bosch ABS/TCS System – Activity 7
7-3
3. Record the stopping distance required to stop a vehicle traveling on wet pavement at 50 MPH.
Set the Road Condition to Dry. Accelerate to 50 MPH. Apply full braking force. 4. Record the stopping distance required to stop a vehicle traveling on dry pavement at 50 MPH.
Set the Road Condition to Ice. Set the ABS System switch to Inactive. Accelerate to 50 MPH. Brake the vehicle to a stop as rapidly as possible without crashing Note: If you crash, just accelerate to 50 MPH and try again. 5. Record your shortest stopping distance. 6. In which direction does the vehicle skid, left or right? Set the Wheel Select to RF. Accelerate to 50 MPH. Brake the vehicle to a stop as rapidly as possible without crashing. 7. Record your shortest stopping distance. 8. In which direction does the vehicle skid, left or right? Note: All Anti-Lock Brake Systems and Traction Control Systems monitor wheel speeds to determine if negative or positive slip is occurring. The determination is made by the rate of change of one wheel’s speed relative to the other vehicle wheels. If the deceleration rate of the wheel is not rapid enough, the system will ignore the wheel slip. The ATech ABS/TCS Trainer was designed to demonstrate this effect by having varying rates of wheel deceleration. At times you may see a wheel stop rotating without any resulting action by the EBTCM. This can occur because the deceleration rate of the wheel was not fast enough to trigger the controller’s response.
7-4
Delco-Bosch ABS/TCS System – Activity 7
Knowledge Check Question*: *9. If a vehicle has a separation between the front wheels of 5 feet and is rounding a curve with a radius of 25 feet, what is the difference in distance traveled for a 180 degree turn. Assume the outside vehicle wheel is at the 25 foot radius.
Turn the Ignition Switch and the System Power OFF. Conclusion: The Anti-Lock Brake System works to reduce stopping distances at all speeds and all road conditions. An additional benefit of the ABS is the ability of the driver to steer the vehicle during a panic stop.
Delco-Bosch ABS/TCS System – Activity 7
7-5
7-6
Delco-Bosch ABS/TCS System – Activity 7
Delco-Bosch ABS/T System
Student Manual
Delco-Bosch ABS/TCS System Activity 8 Hydraulic System Part III Performance Objectives: The purpose of this activity is to study and observe of the operation of the Traction Control System. Tools and Materials: ATech Model 1431/40 Delco-Bosch ABS/TCS System Trainer References: None
Delco-Bosch ABS/TCS System – Activity 8
8-1
8.2
Delco-Bosch ABS/TCS System – Activity 8
On- Trainer Worksheet Activity 8 Set-Up: Before operating the ATech Trainer, perform the following Set-Up Procedure. • Make sure the Four Wheel Sensor/Harness Switches on each side of the vehicle are in the Connect position. • Make sure the EBTCM/BPMV Switch is in the Connect position. • Set the Wheel Select Knob to LF (left front). • Set the Road Conditions Switch to Ice. • Set the ABS System Switch to Inactive. • Set the TCS Operation - ABS Operation Switch to TCS Operation. • Locate the “Power Block” in the lower right-hand corner of the ABS/TCS Board and turn System Power ON. • Connect your Scan Tool and initialize. • Turn Ignition Switch ON. TCS Demonstration: The TCS Demonstration Mode on the trainer allows the student to accelerate to approximately 30 MPH. • Set the Wheel Select Knob to LF (left front). • Set the Road Conditions Switch to Dry. • Set the ABS System Switch to Inactive. • Set the TCS Operation - ABS Operation Switch to TCS Operation. • Press the Gas Pedal all the way down (wide open throttle). 1. According to the Starting/Stopping Distance Display, how many feet did it take to reach 30 MPH?
Release the Gas Pedal and press the Brake to return to 0 MPH. Set the Road Conditions Switch to Wet. Press the Gas Pedal all the way down (wide open throttle).
Delco-Bosch ABS/TCS System – Activity 8
8-3
2. According to the Starting/Stopping Distance Display, how many feet did it take to reach 30 MPH?
Release the Gas Pedal and press the Brake to return to 0 MPH. Set the Road Conditions Switch to Snow. Press the Gas Pedal all the way down (wide open throttle). 3. According to the Starting/Stopping Distance Display, how many feet did it take to reach 30 MPH?
Release the Gas Pedal and press the Brake to return to 0 MPH. Set the Road Conditions switch to Ice. Press the Gas Pedal all the way down (wide open throttle). 4. According to the Starting/Stopping Distance Display, how many feet did it take to reach 30 MPH?
5. List the Solenoids that are activated during the acceleration.
8-4
Delco-Bosch ABS/TCS System –Activity 8
Starting Distance without TCS: The trainer allows the student to compete against the TCS System in accelerating the vehicle to 30 MPH. As you accelerate, watch the skid indicator for excessive acceleration. If you accelerate too rapidly, the vehicle will start to skid off the road as shown on the LCD Display. If you crash, no distance will be displayed. If you accelerate and reach 30 MPH without crashing but the distance is greater than the TCS value, you can brake and try again. Press the TCS System On/Off Switch to turn ON the TCS Off Light. Accelerate to 30 MPH as rapidly as possible without crashing. 6. Try this a few times and record your best starting distance. Note: The TCS System can be beat but it takes almost perfect acceleration. 7. Which direction does the vehicle skid on the display, left or right? Set the Road Condition Switch to Snow. Set the Wheel Select to RF. Note: No action will occur if the Wheel Select Knob is set to either of the rear wheels. Accelerate to 30 MPH as rapidly as possible without crashing. 8. Try this a few times and record your best starting distance. 9. Which direction does the vehicle skid on the display, left or right? Turn the Ignition Switch OFF. Conclusion: The Traction Control System improves vehicle acceleration capability on all road conditions. This is accomplished through the control of engine input torque and selective wheel braking.
Delco-Bosch ABS/TCS System – Activity 8
8-5
8.6
Delco-Bosch ABS/TCS System –Activity 8
Delco-Bosch ABS/T System
Student Manual
Delco-Bosch ABS/TCS System Activity 9 Power On Self–Test Performance Objectives: The purpose of this activity is to review the diagnosis procedure and observe system diagnostics. Tools and Materials: • ATech Model 1431/40 Delco-Bosch ABS/TCS System Trainer • Scan Tool (one of the following) ➢Tech 1 with GM Chassis Cartridge and suitable adapters for J1962 Connector ➢OTC Monitor 4000 enhanced with ABS 98 Cartridge, 3305-73 System Smart Cable, and 3306-03 or 3306-07 GM System Smart 25 Pin Insert References: • Bosch 5 Series ABS/TCS Reference Book • Service Manual Information
Delco-Bosch ABS/TCS System – Activity 9
9-1
Read Page 4-1 in the Reference Book and answer the following questions. Auto Test: 1. When does the EBTCM perform an Auto Test?
2. List the items checked during an Auto Test.
3. When the EBTCM detects a fault, it may: a. b. c.
Read pages 4-3 and 4-4 in the Reference Book and answer the following questions. Note: Some of the diagnostic procedures that can be conducted with the Tech 1 or Tech 2 Scan Tool are unavailable to other scan tool manufacturers and will not be discussed in this program. If they are available to you, verify their operation with your instructor before using on the trainer. Strategy Based Diagnostics: 4. The third step in Strategy Based Diagnostics is:
5. The last step in Strategy Based Diagnostics is: 6. List the possible causes of intermittent conditions. a. b. c. d. e. f. g.
9-2
Delco-Bosch ABS/TCS System –Activity 9
Conclusion: Hard DTCs (the term “hard” means they are always present) cannot be cleared by the Scan Tool until they are physically repaired. If a trouble clears itself, the DTC code will disappear on next ignition cycle and system will be operational.
Delco-Bosch ABS/TCS System – Activity 9
9-3
9.4
Delco-Bosch ABS/TCS System – Activity 9
On Trainer Worksheet Activity 9 Set-Up: Before operating the ATech Trainer, perform the following Set-Up Procedure. • Make sure the Four Wheel Sensor/Harness Switches on each side of the vehicle are in the Connect position. • Make sure the EBTCM/BPMV Switch is in the Connect position. • Set the Wheel Select Knob to LF (left front). • Set the Road Conditions Switch to Ice. • Set the ABS System Switch to Active. • Set the TCS Operation - ABS Operation Switch to ABS Operation. • Locate the “Power Block” in the lower right-hand corner of the ABS/TCS Board and turn System Power ON. • Connect your Scan tool and initialize. • Turn the Ignition Switch ON. 1. List the lights that are activated during the self diagnostics:
• Read out the DTCs of the system with the Scan Tool and clear them if necessary. • Turn the Ignition Switch OFF. • Carefully remove the RF Isolation Indicator Lamp (unscrew the lens cover which also contains the lamp). Turn the Ignition Switch ON. 2. What lamps remain lit after the initial self-test procedure of the EBTCM?
Delco-Bosch ABS/TCS System – Activity 9
9-5
3. Using the Scan Tool, determine what Fault Code (DTC) is present in the system. 4. From the Service Manual, what does this code represent?
5. Attempt to clear this DTC with the Scan Tool. Will the DTC clear? Carefully reinstall the RF Isolation Lamp. (Caution: Do Not Over Tighten) 6. Attempt to clear the DTC with the Scan Tool. Will the DTC clear? Turn the Ignition Switch OFF and remove the RF Isolation Lamp. Turn the Ignition Switch ON. 7. Is DTC present? Reinstall lamp. (Caution: Do Not Over Tighten) Turn the Ignition Switch Off and wait 10 seconds. Turn the Ignition Switch ON. 8. Is the DTC still present? Turn the Ignition Switch OFF.
9-6
Delco-Bosch ABS/TCS System – Activity 9
Delco-Bosch ABS/T System
Student Manual
Delco-Bosch ABS/TCS System Activity 10 Continuous Self-Test
Performance Objectives: The purpose of this activity is to review the diagnosis procedure and observe system self-test diagnostics. Tools and Materials: • ATech Model 1431/40 Delco-Bosch ABS/TCS System Trainer • Meter for measuring Volts and Ohms • Scan Tool (one of the following) ➢Tech 1 with GM Chassis Cartridge and suitable adapters for J1962 Connector ➢OTC Monitor 4000 enhanced with ABS 98 Cartridge, 3305-73 System Smart Cable, and 3306-03 or 3306-07 GM System Smart 25 Pin Insert References: • Service Manual Information The Power On Self-Test procedure of the EBTCM was investigated in the previous activity. This activity will illustrate the continuous system self-testing capability of the EBTCM. Obviously, it would enhance safety if the EBTCM could know the instant a wiring harness connector became faulted (open or shorted), a sensor failed, or a solenoid failed.
Delco-Bosch ABS/TCS System - Activity 10
10-1
10.2
Delco-Bosch ABS/TCS System - Activity 10
On-Trainer Worksheet Activity 10 Set-Up: Before operating the ATech Trainer, perform the following Set-Up Procedure. • Make sure the Four Wheel Sensor/Harness Switches on each side of the vehicle are in the Connect position. • Make sure the EBTCM/BPMV Switch is in the Connect position. • Set the Wheel Select Knob to LF (left front). • Set the Conditions Switch to Ice. • Set the ABS System Switch to Active. • Set the TCS Operation - ABS Operation Switch to ABS Operation. • Locate the “Power Block” in the lower right-hand corner of the ABS/TCS Board and turn System Power ON. • Connect your Scan tool and initialize. • Turn the Ignition Switch ON. • Read out the DTCs of the system with the Scan Tool and clear them if necessary. • Turn the Ignition Switch OFF. • Carefully remove the RF Isolation Indicator Lamp (unscrew the lens cover which also contains the lamp). • Turn the Ignition Switch ON. 1. What lamps remain lit after the initial self-test procedure of the EBTCM?
2. Using the Scan Tool, determine what fault code (DTC) is present in the system. 3. From the Service Manual Information page 5E2-82, what does this code represent?
Note: In performing the service diagnostic procedure, the following differences should be observed: ➢ Any digital volt ohm meter can be substituted for the J39200. ➢ The J41247 breakout box is not needed because the connections are broken out on the front panel of the ATech unit. ➢ To remove the EBTCM from the BPMV on the trainer, set the EBTCM/BPMV Connection Switch to Disconnect. The System Power Switch must be ON to perform the disconnect. The Ignition Switch must be OFF. ➢ Use the tip jacks on the front panel to measure between terminals requested in the diagnostic procedure. Delco-Bosch ABS/TCS System – Activity 10
10-3
Perform the diagnostic procedure on page 5E2-83 in the Service Manual Information to answer the following questions. 4. Describe the problem you found on the trainer.
5. What is the solution given for the problem in the diagnostic procedure?
Reinstall lamp. (Caution: Do not Over Tighten) Ignition should be OFF. (from diagnostic procedure) Set the trainer EBTCM/BPMV Switch to Connect. Turn the Ignition Switch ON. Check for Fault Codes (DTCs) in the system with the Scan Tool. If any are present, clear them with the Scan Tool. Set the LF Wheel Sensor Connect/Disconnect Switch to Disconnect. 6. How long after you set the switch to disconnect does it take for the EBTCM to disable the system? The system is indicated as non-operational by the TCS Off and Anti-Lock Lights.
7. What DTC is set by the system for this fault? Set the LF Wheel Sensor Connect/Disconnect Switch to Connect. Clear the DTC with the Scan Tool Turn the Ignition Switch OFF. Conclusion: The EBTCM performs a self-diagnostic test when the Ignition Switch is turned on to check Pump Motor, Solenoid Valves, and Wheel Speed Sensors. It also performs a continuous test to monitor the system as it is being used. If the EBTCM determines that a possible system malfunction has occurred, it instantly disables the system and indicates to the vehicle operator through the TCS Off and ABS Warning Lights.
10.4
Delco-Bosch ABS/TCS System – Activity 10
Delco-Bosch ABS/TCS System Student Manual
Delco-Bosch ABS/TCS System Activity 11 On-Vehicle Performance Objectives: The purpose of this activity is to study the On-Vehicle service, repair and replacement procedures. Tools and Materials: • ATech Model 1431/40 Delco-Bosch ABS/TCS System Trainer References: • Service Manual Information This activity is a study and review of On-Vehicle service procedures as related to the Delco-Bosch 5 ABS/TCS. These discussions should be followed by actual On-Vehicle operations to ensure that you understand the procedures discussed. Coordinate the On-Vehicle activities with your instructor.
Delco-Bosch ABS/TCS System – Activity 11
11-1
Read page 5E2-102 from the Service Manual Information and answer the following questions. Safety Procedures: 1. Before performing electric welding procedures, unplug the Harness Connector. 2. When charging a battery, always disconnect the battery 3. Wheel Speed Sensors are to be pushed in place by force into place.
cable. only. Do not
4. If any hydraulic component is removed or disconnected, it may be necessary to:
5. Use of tire sizes other than those recommended may result in a reduction in the:
Knowledge Check Questions*: *6. What is the purpose of “bleeding” a brake system?
*7. Why is “bleeding” necessary?
8. From page 5E2-104, what is the first step in removing the Brake Pressure Modulator Valve?
9. If the brake pipes are incorrectly connected (switched) during installation of the Brake Pressure Modulator Valve, what is the result on system operation?
10. How can this condition be detected?
11. What is the torque setting for the brake pipefittings to the Brake Pressure Modulator Valve?
11-2
Delco-Bosch ABS/TCS System – Activity 11
Component Locations: 12. From Figure 5 on page 5E2-105, list the component associated with the following numbers. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 13. From page 5E2-106, are the Left and Right Front Wheel Sensors interchangeable? 14. Are the Left and Right Rear Wheel Sensors interchangeable? 15. From Figure 7 on page 5E2-107, identify the components associated with the following numbers. 1. 2. 3. 4. Conclusion: Extreme care must be taken to ensure that the hydraulic brake pipes are reinstalled in the same positions on the BPMV. Failure to do so can result in system failure and injury to personnel.
Delco-Bosch ABS/TCS System – Activity 11
11-3
11.4
Delco-Bosch ABS/TCS System – Activity 11
Model 1431/40
Delco-Bosch ABS/TCS System NATEF TASKS Record Keeping Sheet Student:
Instructor:
At this point in the program, ask your instructor to review your ability to perform the following NATEF tasks and record your progress.
V.
BRAKES G. Antilock Brake and Traction Control System
1.
Identify and inspect antilock brake system (ABS) components; determine necessary action.
3.
Diagnose antilock brake system (ABS) electronic control(s) and components using self-diagnosis and/or recommended test equipment; determine necessary action.
5.
Bleed the antilock brake system’s (ABS) front and rear hydraulic circuits.
6.
Remove and install antilock brake system (ABS) electrical/electronic and hydraulic components.
7.
Test, diagnose and service ABS speed sensors, toothed ring (tone wheel). and circuits using a graphing multimeter (GMM)/digital storage oscilloscope (DSO) (includes output signal, resistance, shorts to voltage/ground, and frequency data).
9.
Identify traction control system components.
VI.
ELECTRICAL/ELECTRONIC SYSTEMS A. General Electrical System Diagnosis
2.
Identify and interpret electrical/electronic system concern; determine necessary action. ATech Supports ASE/NATEF Delco-Bosch ABC/TCS System – 2008
Date
Grade
1
6. Use wiring diagrams during diagnosis of electrical circuit problems. 7. Demonstrate the proper use of a digital multimeter (DMM) during diagnosis of electrical circuit problems including; source voltage, voltage drop, current flow, and resistance. 9.
Check electrical/electronic circuit waveforms; interpret readings and determine needed repairs.
11.
Locate shorts, grounds, opens, and resistance problems in electrical/ electronic circuits; determine necessary action.
13.
Inspect and test fusible links, circuit breakers, and fuses; determine necessary action.
14.
Inspect and test switches, connectors, relays, solid state devices, and wires of electrical/electronic circuits; perform necessary action.
ATech Supports ASE/NATEF Delco-Bosch ABC/TCS System – 2008 2
MODEL 1431/40
Delco-Bosch ABS/TCS System Reference Book
Published by ATech Training, Inc. 12290 Chandler Drive Walton, KY 41094 USA Phone: (859) 485-7229 Fax: (859) 485-7299 Email:
[email protected] Website: www.atechtraining.com
MODEL 1431/40
Delco-Bosch ABS/TCS System Service Manual Information
Pontiac: Bonneville Oldsmobile: Eighty-Eight, LSS, & Ninety-Eight Buick: Le Sabre & Park Avenue VIN#: 1G3HN52K8T4816905
Published by ATech Training, Inc. 12290 Chandler Drive Walton, KY 41094 USA Phone: (859) 485-7229 Fax: (859) 485-7299 Email:
[email protected] Website: www.atechtraining.com
Service Manual Information
1996 PARK AVENUE, LESABRE, NINETY-EIGHT, EIGHTY-EIGHT AND BONNEVILLE SERVICE MANUAL BOOK 1 FORWARD
TABLE OF CONTENTS
This manual provides information on diagnosis, service procedures, adjustments, and specifications for the 1996 Park Avenue, LeSabre, Ninety-Eight, Eighty-Eight, and Bonneville. An understanding of the material contained in this manual and in the appropriate Dealer Service Bulletins will help technicians to better service vehicle owners. The 1996 Park Avenue, LeSabre, Ninety-Eight, Eighty-Eight, and Bonneville service manual information has been separated into two books: BOOK 1 Contains all sections EXCEPT Driveability and Emissions (Sections 6E and 6E3), Automatic Transaxle Diagnosis (7A-5A), and Electrical Diagnosis (Section 8A). BOOK 2 Contains Driveability and Emissions (Sections 6E and 6E3), Automatic Transaxle Diagnosis (7A-5A), and Electrical Diagnosis (Section 8A). Information on unit repair (overhaul) can be found in the 1996Transmission/Transaxle/Transfer Case Unit Repair Manual, GMPT/96-TURM (available separately). It contains information on automatic and manual transmissions and transaxles, and transfer cases for all GM passenger cars and light duty trucks, including the fluid flow and circuit description information. When reference is made in these manuals to a brand name, number, or specific tool, an equivalent product may be used in place of the recommended item. All information, illustrations, and specifications contained in these manuals are based on the latest product information available at the time of publication approval. The right is reserved to make changes at any time without notice.
SECTION NO.
SUBJECT
0
GENERAL INFORMATION
1
HEATING AND AIR CONDITIONING
3
STEERING, SUSPENSION, TIRES AND WHEELS
4
DRIVE AXLE
5
BRAKES
6
ENGINE
7
TRANSAXLE
8
ELECTRICAL – BODY AND CHASSIS
9
ACCESSORIES
10
BODY SERVICE
INDEX
ALPHABETICAL INDEX
NORTH AMERICAN OPERATIONS General Motors Corporation WARREN, MICHIGAN 48010 © 1995 GENERAL MOTORS CORPORATION
All Rights Reserved
6-25-95
• Litho in U.S.A.
1996 PARK AVENUE, LESABRE, NINETY-EIGHT, EIGHTY-EIGHT, AND BONNEVILLE SERVICE MANUAL CONTENTS - BOOK 1 TABLE OF CONTENTS GENERAL INFORMATION General Information Maintenance and Lubrication HEATNG AND AIR CONDITIONING Heater, Ventilation and Air Conditioning Manual Air Conditioning Automatic Control Air Conditioning HD6/HT6 Air Conditioning Compressor STEERING, SUSPENSION, TIRES AND WHEELS Diagnosis Wheel Alignment Power Steering Gear and Pump Power Steering Gear and Pump – Unit Repair Front Suspension Rear Suspension Electronic Level Control Tires and Wheels Steering Wheel and Column On-Vehicle Service Supplemental Inflatable Restraint (SIR) Tilt Steering Column Unit Repair – Column Shift Supplemental Inflatable Restraint (SIR) Tilt Steering Column Unit Repair – Floor Shift Computer Command Ride DRIVE AXLE Drive Axle Drive Axle – Unit Repair BRAKES WITH TRACTION CONTROL General Brakes Master Cylinder Front Disc Brake Caliper Drum Brake Vacuum Booster System Antilock Brake System (ABS) and Traction Control System (TCS) Parking Brake ENGINE Engine General Information 3800 Engine VIN Code K & 1 On-Vehicle Service 3800 Engine VIN Code K & 1 Unit Repair Cooling and Radiator Engine Fuel Engine Electrical
SECTION 0A 0B 1B 1B1 1C 1D2
3 3A 3B 3B1 3C 3D 3D1 3E 3F 3F5A 3F5B 3G
4D 4D1 5 5A 5B1 5C1 5D1 5E2 5F 6 6A8A 6A8B 6B 6C 6D
TABLE OF CONTENTS Battery Cranking System Charging System Ignition System Engine Wiring Exhaust System Supercharger TRANSAXLE For Unit Repair, see 1996 Transmission/Transaxle/Transfer Case Unit Repair Manual Automatic Transaxle General Information 4T60-E Automatic Transaxle On-Vehicle Service 4T60-E Automatic Transaxle Diagnosis (See Book 2) ELECTRICAL – BODY AND CHASSIS Electrical Lighting Systems and Horns Instrument Panel, Gages, and Console Windshield Wiper/Washer System ACCESSORIES Audio Systems Cruise Control Twilight Sentinel Theft Deterrent Systems Engine Coolant Heater Supplemental Inflatable Restraint (SIR) System Remote Function Actuator Electronic Compass Head Up Display (HUD) BODY SERVICE Introduction General Body Service Stationary Widows Frame and Underbody Bumpers Body Front End Doors Rear Quarters Body Rear End Roof Seats and Carpet Seat Belts ALPHABETICAL INDEX
SECTION 6D1 6D2 6D3 6D4 6D5 6F 6G
7 7A
8 8B 8C 8E 9 9A 9B 9C 9D 9E 9J 9K 9L 9M 10 10-1 10-2 10-3 10-4 10-5 10-6 10-7 10-8 10-9 10-10 10-11 INDEX-1
CONTENTS – BOOK 2 TABLE OF CONTENTS Engine Driveability 3800 Driveability & Emissions 4T60-E Automatic Transaxle Diagnosis
SECTION 6E 6E3 7A-5A
TABLE OF CONTENTS
SECTION
ELECTRICAL – BODY AND CHASSIS Electrical Diagnosis ALPHABETICAL INDEX
8A INDEX-1
ABS/TCS 5E2-5 “BRAKE” Warning Lamp
SYSTEM COMPONENTS
The red “BRAKE” lamp in the instrument cluster will illuminate to warn the driver of conditions in the brake system which may result in reduced braking ability. It will also illuminate when the parking brake is applied or not fully released, or if the brake fluid level switch is closed. The “BRAKE” warning lamp will stay illuminated until the condition has been repaired. Refer to SECTION 5.
Brake Pressure Modulator Valve (BPMV) Figure 2
“ANTILOCK” Indicator Lamp The “ANTILOCK” warning lamp is also located in the instrument cluster and will illuminate if a malfunction in the ABS is detected by the Electronic Brake (and Traction) Control Module (EBCM/EBTCM). The “ANTILOCK” lamp informs the driver that a condition exists which results in turning off the antilock brake and traction control function. If only the ‘ANTILOCK” lamp is on, normal braking with full power assist is available. If the “BRAKE” and “ANTILOCK” lamps are on, a problem may exist in the hydraulic brake system. Refer to SECTION 5. Conditions for the “ANTILOCK” lamp to turn on are as follows: 1. ABS malfunction detected. As previously described, the “ANTILOCK” lamp turns on when a problem has been found in the ABS. The “ANTILOCK” lamp indicates that the ABS and TCS have been disabled. 2. Instrument panel bulb check. When the ignition is turned to “RUN,” the “ANTILOCK” lamp will turn on for approximately three seconds and then turn off. The “ANTILOCK” lamp should turn off with the ignition switch in the “RUN” position. ! Important • Illumination of the “BRAKE” warning lamp may indicate reduced braking ability. • Illumination of the “ANTILOCK” lamp without the “BRAKE” warning lamp on indicates only that antilock braking is no longer available. Power assisted braking without antilock control is still available. • Refer to SECTION 5 for diagnosis of any condition which causes the “BRAKE” warning lamp to illuminate. • Refer to “Diagnosis” in this section for any condition which causes the “ANTILOCK” warning lamp to illuminate. “TRACTION OFF” Lamp Illumination of the “TRACTION OFF” lamp indicates that a malfunction has occurred and the traction control system is disabled, or the “TCS OFF” switch has been activated. “TRACTION ACTIVE” Lamp Illumination of the “TRACTION ACTIVE” lamp indicates that traction control is active. This lamp does not mean a malfunction has occurred or service is needed.
The Brake Pressure Modulator Valve (BPMV), mounted on the left front side of the engine compartment. provides brake fluid modulation for each of the individual wheel circuits as required during antilock braking. During the antilock mode, the BPMV can maintain or reduce brake fluid pressure independent of the pressure generated in the master cylinder. The BPMV does not provide more pressure than is applied by the master cylinder during braking. The EBTCM/BPMV assembly can apply the rear brakes during traction control mode. With the exception of the EBCM/EBTCM, the Brake Pressure Modulator Valve (BPMV) is an integral, nonserviceable component. The BPMV should never be disassembled. The Brake Pressure Modulator Valve (BPMV) uses a four circuit configuration during normal braking. Individual circuits are provided for the left front and right rear wheels, and right front and left rear wheels. The diagonal circuits are hydraulically isolated so that a leak or malfunction in one circuit will allow continued braking ability on the other. The Brake Pressure Modulator Valve (BPMV) consists of several other components which are described as follows: Pump Motor The Brake Pressure Modulator Valve (BPMV) also contains a small pump which circulates brake fluid back to the master cylinder circuit during the antilock mode. The pump is located in the Brake Pressure Modulator Valve and cannot be serviced separately. Solenoid Valves The solenoid valves of the modulator are an integral portion of the Brake Pressure Modulator Valve (BPMV) and are not serviceable. The solenoid valves increase, decrease or maintain brake fluid pressure to the individual wheel circuits. The solenoid valves are controlled by the EBCM/EBTCM, which commands the valves to their correct position during antilock braking. During normal braking, the valves are positioned to pressure increase, or “Open.” Braking is accomplished as a normal power assist system. During ABS or TCS mode, the pressure in each hydraulic circuit can be increased, decreased or held constant by changing the valve positions to various combinations. Electronic Brake (and Traction) Control Module (EBCM/EBTCM) Figure 2 The EBCM/EBTCM is a small control microprocessor, which monitors the speed of each wheel and the electrical status of the Brake Pressure Modulator Valve (BPMV).
5E2 ABS/TCS
ABS/TCS 5E2-13
5E2-14 ABS/TCS
LF WHEEL SPEED SENSOR
RF WHEEL SPEED SENSOR
LR WHEEL SPEED SENSOR
B B
A
0.5 BLK
B
830
B 0.5 LT BLU
B
HI
REQUESTED TORQUE OUTPUT
1
0.35
463
ORN/BLK
H4 0.35 ORN/BLK
14
10
885
HI
11 LO
LO RR WSS INPUT
MAGNASTEER HI
30
C
0.35 TAN
CONTROL MODULE (PCM)
F
0.35 GRA 1787 0.35 TAN 800B
0.35 WHT
800A
G6
0.35 TAN 800B 0.35 TAN
E10
SENSING
AND DIAGNOSTIC (MODULE (SDM)
C2
G2
345
C101
800A 1.35 TAN 800B
A3
MAGNASTEER LO
800B
S226
B3
ELECTRICONIC BRAKE AND TRACTION CONTROL MODULE (EBCM/EBTCM)
P100 883
27 HI
LR WSS INPUT
800A
0.35 TAN
POWERTRAIN
P403
0.5 WHT
26
LO
C101
TORQUE INPUT
15
0.35 TAN
C415
882
UART DATA LINES
464
33
B
0.5 BRN
15
REQUESTED DELIVERED TORQUE INPUT
884
0.5 RED
RF WSS INPUT
14
A7 0.35 TAN/BLK 463
A
833
25 HI
464
0.5 883 WHT
C 0.5 BLK
DELIVERED TORQUE INPUT
0.36 TAN/BLK
882
885
P101
9 LO
A
D
0.5 TAN
LF WSS INPUT
0.5 BLK
0.5 WHT
C121
872
873
24
884
833
A
0.5 DK GRN
0.5 YEL
0.5 BLK
0.5 WHT
C120
830
8
872
873
A
B
A
0.5 BLK
0.5 WHT
A
RR WHEEL SPEED SENSOR
E11
0.35 GRA 1787 0.35 WHT
HVAC
PROGRAMMER (PONTIAC W/ C68 OR BUICK/ OLDSMOBILE W/ CJ2 ONLY)
A
345
B
C101
0.35 TAN 800
MAGNASTEER ACTUATOR 05-23-95 CHT0018A44
ABS/TCS 5E2-20 ABS/TCS DTC TABLE DTC 11 14 16 17 21 22 23 24 25 26 27 28 32 33 34 35 36 37 38 41 42 43 55xx 56xx 61 62 63 64 65 66 67 68 71 72 73 74 75 76 77 78 91 93 94 95
DESCRIPTION ABS Warning Lamp Circuit Malfunction Solenoid Valve Relay Contact Circuit Open Solenoid Valve Relay Coil Circuit Open BPMV Pump Motor Relay Contact Circuit Open LF Wheel Speed Sensor Input Signal - 0 RF Wheel Speed Sensor Input Signal - 0 LR Wheel Speed Sensor Input Signal - 0 RR Wheel Speed Sensor Input Signal - 0 LF WSS - Excessive Wheel Speed Variation RF WSS - Excessive Wheel Speed Variation LR WSS - Excessive Wheel Speed Variation RR WSS - Excessive Wheel Speed Variation LF Wheel Speed Sensor Circuit Open Or Shorted (1 of 2) RF Wheel Speed Sensor Circuit Open Or Shorted (1 of 2) LR Wheel Speed Sensor Circuit Open Or Shorted (1 of 2) RR Wheel Speed Sensor Circuit Open Or Shorted (1 of 2) Low System Voltage High System Voltage Brake Thermal Model Limit Exceeded Magnasteer Circuit Malfunction BPMV Pump Motor Ground Circuit Open BPMV Pump Motor Stalled (1 of 2) EBTCM Internal Malfunction (ABS/TCS Disabled) EBTCM Internal Malfunction LF Hold Valve Solenoid Malfunction LF Release Valve Solenoid Malfunction RF Hold Valve Solenoid Malfunction RF Release Valve Solenoid Malfunction LR Hold Valve Solenoid Malfunction LR Release Valve Solenoid Malfunction RR Hold Valve Solenoid Malfunction RR Release Valve Solenoid Malfunction LF TCS Master Cylinder Isolation Valve Malfunction LF TCS Prime Valve Malfunction RF TCS Master Cylinder Isolation Valve Malfunction RF TCS Prime Valve Malfunction PCM Serial Data Malfunction Delivered Torque PWM Signal Malfunction PCM Detected EBTCM To PCM Interface Malfunction TCS Temporarily Inhibited By PCM Open Brake Lamp Switch Circuit During Deceleration DTC 91 Set In Current Or Previous Ignition Cycle Brake Lamp Switch Circuit Always Active Brake Lamp Switch Circuit Open
PAGE 5E2-40 5E2-42 5E2-44 5E2-46 5E2-48 5E2-48 5E2-48 5E2-48 5E2-50 5E2-50 5E2-50 5E2-50 5E2-54 5E2-52 5E2-52 5E2-52 5E2-56 5E2-58 5E2-60 Refer to Section 8A-45 5E2-64 5E2-66 5E2-70 5E2-72 5E2-74 5R2-76 5R2-74 5E2-76 5E2-74 5E2-76 5E2-74 5E2-76 5E2-78 5E2-80 5E2-82 5E2-84 5E2-86 5E2-88 5E2-90 5E2-92 5E2-94 5E2-96 5E2-98 5E2-100
ABS/TCS 5E2-55 DTC (s) 32, 33, 34, 35 (Page 2 of 2) WHEEL SPEED SENSOR CIRCUIT OPEN OR SHORTED
IMPORTANT: • WHEEL SPEED SENSOR INTERMITTENT MALFUNCTIONS MAY BE DIFFICULT TO LOCATE. CARE SHOULD BE TAKEN NOT TO DISTURB ANY ELECTRICAL CONNECTIONS PRIOR TO AN INDICATED STEP OF THIS CHART. THIS WILL ENSURE THAT AN INTERMITTENT CONNECTION WILL NOT BE CORRECTED BEFORE THE SOURCE OF THE MALFUNCTION IS FOUND.
DIAGNOSIS CONTINUED FROM PAGE 1 OF 2 OF THIS DTC CHART.
6
• DISCONNECT AFFECTED WHEEL SPEED SENSOR DIRECTLY AT SENSOR. •USING J 39200. MEASURE THE RESISTANCE BETWEEN TERMINALS “24” - LF, “25” - RF, “26” - LR, “27” - RR OF THE EBTCM HARNESS CONNECTOR AND TERMINAL “A” OF THE AFFECTED WHEEL SPEED SENSOR HARNESS CONNECTOR. IS RESISTANCE 2 OR LESS?
YES
7
• USING J 39200, MEASURE THE RESISTANCE BETWEEN TERMINAL “8” - LF, “9” - RF, “10” - LR “11” - RR OF THE 32-WAY EBTCM HARNESS CONNECTOR AND TERMINAL “B” OF THE AFFECTED WHEEL SPEED. IS RESISTANCE 2 OR LESS?
YES
8
• USING J 39200, MEASURE THE RESISTANCE BETWEEN TERMINAL “A” AND TERMINAL “B” OF THE AFFECTED WHEEL SPEED SENSOR CONNECTOR. IS RESISTANCE BETWEEN 900 AND 1300 ?
YES
NO
REPAIR HIGH RESISTANCE IN AFFECTED CIRCUIT. (WHEEL SPEED SENSOR JUMPER MUST BE REPLACED IF DAMAGED).
NO
REPAIR HIGH RESISTANCE IN AFFECTED CIRCUIT. (WHEEL SPEED SENSOR JUMPER MUST BE REPLACED IF DAMAGED).
NO
REPLACE WHEEL SPEED SENSOR. MALFUNCTION IS INTERMITTENT. INSPECT ALL CONNECTORS AND HARNESSES FOR DAMAGE WHICH MAY RESULT IN HIGH RESISTANCE WHEN ALL COMPONENTS ARE CONNECTED. REFER TO “DIAGNOSTIC AIDS” ON FACING PAGE FOR MORE INFORMATION. REPAIR ALL DAMAGE IF FOUND.
WHEN ALL DIAGNOSIS AND REPAIRS ARE COMPLETED, CLEAR DTC(s) AND VERIFY PROPER OPERATION.
5E2 ABS/TCS
ABS/TCS 5E2-60 BRAKE PRESSURE MODULATOR VALVE (BPMV) WITH ELECTRONIC BRAKE TRACTION CONTROL MODULE (EBTCM)
BPMV
EBTCM
DTC 38 BRAKE THERMAL MODEL LIMIT EXCEEDED Circuit Description: The EBTCM monitors vehicle speed, deceleration, ABS/TCS activation, and brake lamp “ON” times to calculate brake rotor temperatures. When brake rotor temperatures are exceeded, TCS is disabled, DTC 38 is set, and the “TCS OFF” indicator is turned “ON” after the next TCS event. If brake usage is reduced during driving, brake rotor cooling is calculated and TCS is reenabled. Excessive braking and/or TCS could result in degraded braking performance or possible damage to the rotors and/or brake pads. DTC Will Set When: DTC 38 could be set when either driven wheel estimated brake rotor temperature exceeds 375C (700F). If either driven wheel estimated brake rotor temperature has exceeded 375C (700F) during ABS or normal braking conditions, the code will not be set until the next TCS activation occurs. The code will not be set and TCS will not be disabled if both rotor estimated temperatures have cooled below 275C (530F) before the next TCS activation. If either driven wheel brake rotor temperatures has exceeded 375C (700F) during TCS then the code will be set immediately, but TCS will not be disabled until the end of the TCS event.
Action Taken: A malfunction code is stored. The “TRACTION OFF” indicator is turned “ON” and TCS is disabled as long as both driven wheel brake rotor temperatures are above 275C (530F). If the rotor temperatures cool below 275C (530F), then the “TRACTION OFF” indicator will be turned off. The DTC stays stored even if TCS has been enabled again. DTC Chart Test Description: Number(s) below refer to circled number(s) on the diagnostic chart. 1. Checks to see if any other DTCs are set. 2. Checks to see if DTC 38 is set as a current code. 3. Lets brakes cool for 20 minutes and then rechecks to see if the Brake Thermal Model (BTM) limit remains exceeded. Diagnostic Aids: Possible causes: • Excessive brake usage • Excessive TCS usage The temperature values are an estimated figure calculated by the EBTCM. If the driven wheel brake rotors are known to be below 275C (530F), and the Brake Lamp Switch is properly adjusted and the Brake Lamp Switch CKT is OK, the likely cause of the malfunction is probably a defective EBTCM.
5E2 ABS/TCS
ABS/TCS 5E2-82
DTC73 RF TCS MASTER CYLINDER ISOLATION VALVE MALFUNCTION Circuit Description: The master cylinder isolation valve solenoid circuit is supplied with battery power when the ignition is in the “RUN” position. The EBTCM controls the valve by grounding the circuit when necessary. DTC Will Set When: The EBTCM senses a discrepancy such as an open, short to ground, or short to voltage in the circuit. Action Taken: A malfunction DTC is stored, ABS/TCS is disabled and the “ANTILOCK” and “TRACTION OFF” indicator lamps are turned “ON.” DTC Chart Test Description: Number(s) below refer to circled number(s) on the diagnostic chart. 1. Checks condition of EBTCM to BPMV connector and for presence of brake fluid in the EBTCM.
2.Checks the integrity of the affected valve solenoid circuitry internal to the BPMV and the valve
solenoid coil. 3.Checks for solenoid circuit short to ground (BPMV case). 4.Uses the Tech 1 to exercise the affected valve solenoid and check it for proper operation. 5.Checks for continued DTC setting after validating that the circuitry and the solenoid valves are good. If DTC resets, the EBTCM is likely malfunctioning.
Diagnostic Aids: It is very important that a thorough inspection of the wiring and connectors be performed. Failure to carefully and fully inspect wiring and connectors may result in misdiagnosis, causing part replacement with reappearance of the malfunction.
5E2-83 ABS/TCS DTC 73 RF TCS MASTER CYLINDER ISOLATION VALVE MALFUNCTION NOTICE: J 39200 TEST LEADS MUST BE “ZEROED” PRIOR TO MAKING ANY RESISTANCE MEASUREMENTS. REFER TO J 39200 USER’S MANUAL. ● IGNITION “OFF.” ● DISCONNECT EBTCM CONNECTOR. ● REMOVE EBTCM FROM BPMV. ● INSPECT EBTCM TO BPMV CONNECTOR FOR CONDITIONS WHICH COULD CAUSE INTERMITTENTS, SUCH AS DAMAGE, CORROSION, POOR TERMINAL CONTACT, OR PRESENCE OF BRAKE FLUID, REFER TO “INTERMITTENTS AND POOR CONNECTIONS” IN SECTION 8A-44, IS CONNECTOR OK AND CAVITY FREE OF BRAKE FLUID?
YES
● INSTALL J 41247 BPMV PINOUT BOX TO BPMV CONNECTOR. ● USING J 39200 MEASURE RESISTANCE BETWEEN J 41247 TERMINALS “7” AND “3”. IS RESISTANCE 8-12 Ω?
YES
● USING J 39200, MEASURE RESISTANCE BETWEEN J 41247 TERMINAL “3” AND BPMV CASE. DOES J 39200 DISPLAY “OL” (INFINITE)?
YES
● REMOVE J 41247. ● RE-CONNECT EBTCM TO BPMV. ● RE-CONNECT EBTCM HARNESS CONNECTOR. ● TURN IGNITION TO “RUN” ● PERFORM TECH 1 “TCS TEST”. DOES “TCS TEST” OPERATE PROPERLY?
YES
● CLEAR DTCs, IGNITION “OFF.” ● DISCONNECT TECH 1, IF CONNECTED. ● TURN IGNITION TO “RUN” DOES DTC 73 RESET?
YES
REPLACE EBTCM.
NO
CONNECTOR CORROSION OR DAMAGE: REPLACE BPMV AND/OR EBTCM. BRAKE FLUID PRESENT: REPLACE BPMV AND EBTCM.
NO
REPLACE BPMV.
NO
REPLACE BPMV.
NO
REPLACE BPMV.
NO
N O
TROUBLE FOUND; SEE “ DIAGNOSTIC AIDS” ON FACING PAGE.
WHEN ALL DIAGNOSIS AND REPAIRS ARE COMPLETED, CLEAR DTC(s) AND VERIFY PROPER OPERATION.
ABS/TCS 5E2-102 ON-VEHICLE SERVICE GENERAL SERVICE PRECAUTIONS NOTICE: The following are general precautions which should be observed when servicing the Antilock Brake System, traction control system and/or other vehicle systems. Failure to observe these precautions may result in Antilock Brake System damage. See “CAUTIONS” and “NOTICES” on page 5E2-1. • Before performing electric welding procedures, unplug the EBCM/EBTCM harness connector. • Always carefully note the routing, position, mounting and location of ABS and TCS wiring, connectors, clips, brackets, etc. ABS and TCS components are extremely sensitive to EMI (electro-magnetic interference). Proper mounting is critical when servicing these components. • Do not use a quick charger for engine starting or for battery charging if the battery is still connected to the vehicle’s electrical system. Failure to do so may cause the brake fuse to fail or cause serious damage to other electrical components. Always disconnect the battery negative cable when charging a battery. • Never disconnect the battery from the electrical system with the engine running. • Never connect or disconnect the EBCM/EBTCM connector with the ignition switch in “RUN.” • Do not attempt to repair the Brake Pressure Modulator Valve (BPMV). • Do not hang the suspension components by the wheel speed sensor cables: cable damage may result. • Do not force the wheel speed sensors into place. The sensors are to be pushed in by hand only. • During painting work, the EBCM/EBTCM may be subjected to a maximum of 95C (203F) for brief periods and a maximum of 85C (184F) for lengthy periods (about two hours). • Many components of the antilock brake system are nonserviceable and must be replaced as assemblies. Do not disassemble any component which is designated as nonserviceable in this section. • When filling the master cylinder use only Supreme 11 (GM 1052542) or equivalent DOT 3 brake fluid. Do not use a container which has been used for petroleum based fluids or a container which is wet with water. Petroleum based fluids will cause swelling and distortion of rubber parts in the hydraulic brake system and water will mix with brake fluid, lowering the fluid boiling point Keep all fluid containers capped to prevent contamination. When bleeding the brake system, follow the recommended manual and pressure bleeding procedures in SECTION 5, to be followed by the “Auto Bleed Procedure” outlined in this section.
• After replacement of the Brake Pressure Modulator Valve (BPMV), EBCM/EBTCM, wheel speed sensors, wiring harness or other work involving the ABS system, the entire ABS system must be checked using the Tech 1 Diagnostic Tester. Refer to “Diagnosis” in this section. The above precautions are not exhaustive and are to be followed when working on an ABS equipped vehicle. Become familiar with the ABS with TCS and how it may be interrelated to other components on the vehicle when performing service work. Notice: Do not use lubricated compressed air on brake parts as damage to rubber components may result. ! Important •If any hydraulic component is removed or disconnected, it may be necessary to bleed all or part of the brake system. The torque values specified are for dry, unlubricated fasteners. • Perform service operations on a clean bench, free from all mineral oil materials. •Use of tire sizes other than those recommended may result in a reduction in the optimal performance of the antilock brake or traction control systems. CHECKING AND ADDING FLUID Refer to SECTION 5 for information on checking and adding brake fluid. BLEEDING BRAKE HYDRAULIC SYSTEM Refer to SECTION 5 for manual and pressure bleeding procedures. Afterwards, perform “Auto Bleed Procedure” outlined in this section. Auto Bleed Procedure The Auto Bleed Procedure is used to provide a complete brake system bleed on Bosch 5 equipped vehicles. The procedure cycles the system valves and runs the pump to purge air from secondary circuits normally closed off during non-ABS/TCS mode operation and bleeding. It is to be used when it is suspected that air has been ingested into the system secondary circuits, or when the Brake Pressure Modulator Valve (BPMV) has been replaced with a new unit. To perform this procedure successfully, the following are required: •Tech One Scan Tool with MSC •A pressure brake bleeder capable of producing at least 30 psi, with suitable adapters and filled with Delco Supreme 11 brake fluid obtained from a sealed container. •A hoist, or suitable stands to support vehicle.
5E2-103 ABS/TCS • A bleeder bottle to receive vented brake fluid. The bottle should be constructed of unbreakable plastic, and should have a clear plastic hose sized to fit snugly on the bleeder valves. The hose should protrude into the bottle, with its end immersed in brake fluid. • An assistant to pump the brake pedal during the procedure. • Suitable safety attire, including safety glasses. NOTICE: The Auto Bleed Procedure may be terminated at any time during the process by selecting the ‘EXIT” button. No further Tech One prompts pertaining to the Auto Bleed procedure will be given. After selecting “EXIT,” relieve bleed pressure and disconnect bleed head from master cylinder, following bleed equipment manufacturers instructions. 1.
Raise vehicle and support. Refer to GENERAL INFORMATION (Section 0A) 2. Remove all four wheels. 3. Inspect brake system for leaks or component damage. Correct all conditions found before starting procedure. 4. Assure vehicle battery is fully charged before beginning procedure. 5. Connect Tech One to DLC. 6. Turn Ignition to “RUN,” do not start engine. 7. Establish communications with Tech One and select ABS/TCS system features. 8. Select “F4: Misc. Tests” 9. Select “F4: Auto Bleed Procedure.” 10. Bleed base brake system as instructed in GENERAL BRAKES (Section 5). 11. Select “ENTER “ button. This conducts several tests which determine whether the ABS/TCS system condition is such that the bleed procedure can be performed. If any malfunctions are detected, the bleed procedure will be aborted. If DTCs are present, the Tech One will display “DTCs PRESENT” or list the DTCs, depending on when the DTCs were set. DTCs can be displayed or cleared as appropriate in the “P2: Trouble Codes” mode. Refer to correct Service Manual section for those DTCs. If test is aborted but no DTCs are listed, go to the “System Functional Check” in this section. Correct all system malfunctions before attempting the bleed procedure again. If a road test is required for diagnosis and brake pedal is “spongy,” perform a conventional brake bleed, achieving a firm pedal before driving vehicle. 12. Connect pressure bleed equipment described earlier, following manufacturer’s instructions. Select “UP” button. 13. Apply bleed pressure, minimum 30 psi. Check for leaks at master cylinder reservoir bleeder cap and correct, if necessary. 14. Have assistant pump brake pedal continuously from this point on, making long, steady strokes. Select “UP”.
15. Open left rear bleeder screw, use Bleeder bottle. Select “ENTER.” 16. Close left rear bleeder screw when prompted. Select “UP” button. 17. Left rear bleed complete. Select “UP.” • Repeat steps 15 through 17 on the right rear brakes. 18. Open right front bleeder screw, use bleeder bottle. Select “ENTER.” 19. Have assistant pump brake pedal continuously, making long, steady strokes. Select “UP” 20. Apply Brake and hold for 10 seconds when prompted. (Tech One will display timer). 21. Release brake when prompted. Wait 10 seconds. • Step 20 and 21 will repeat three more times. 22. Close right front bleeder screw when prompted. Select “UP” button. 23. Right front bleed complete. Select “UP” 24. Open left front bleeder screw, use bleeder bottle. Select “ENTER.” 25. Have assistant pump brake pedal continuously, making long, steady strokes. Select “UP” 26. Apply Brake and hold for 10 seconds when prompted. (Tech One will display timer). 27. Release brake when prompted. Wait 10 seconds. Step 26 and 27 will repeat three more times. 28. Close left front bleeder screw when prompted. Select “UP” button. 29. Left front bleed complete. Select “UP” At this time, the Tech One performs several tests to reverify system operation. The Tech One does not verify bleed success. If any malfunctions are detected, relieve bleed pressure and disconnect bleed equipment, following manufacturers instructions. If DTCs are present, the Tech One will display them. DTCs can be cleared in the “F2: Trouble Codes “ mode. Select “EXIT” to return to Tech One main menu. Refer to correct Service Manual section for DTCs found. If test is aborted but no DTCs are listed, go to the “System Functional Check” in this section. Correct all system malfunctions before attempting to repeat the bleed procedure. 30. If screen displays “BLEED PROCEDURE COMPLETE,” select “UP” button. 31. Release bleed pressure, following bleed equipment manufacturers instructions. Select “UP” button. 32. Disconnect bleed equipment. Clean up any spilled brake fluid by wiping up as much as possible, then flushing area with water. Do not allow any water to enter master cylinder reservoir. Select “EXIT”. 33. Depress brake pedal. It should be high and firm. If not, re-inspect brake system thoroughly for any conditions which could cause excess brake pedal travel. See Section 5 for details. If brake system is OK, and excess pedal travel persists, repeat Auto Bleed Procedure.
ABS/TCS 5E2-104
BRAKE PRESSURE MODULATOR VALVE (BPMV) Figure 5 CAUTION: For safety reasons, the Brake Pressure Modulator Valve (BPMV) must not be repaired, the complete unit must be replaced. With the exception of the EBCM/EBTCM, no screws may be loosened, if screws are loosened, it will not be possible to get the brake. circuits leak-tight and personal injury may result. CAUTION: Refer to “Caution” under “Disconnecting the Battery Negative Cable” in SECTION 0A. NOTICE: The use of rubber hoses or parts other than those specified for the ABS may lead to functional problems requiring major overhaul. Remove or Disconnect 1. Battery negative Cable, refer to Section 6D1. 2. Air cleaner assembly and PCM cover. Refer to Section 6C. 3. EBCM/EBTCM harness connector and BPMV motor ground cable connector. 4. Brake pipe fittings. ! Important • Note location of brake pipes for aid during installation. NOTICE: When removing the brake pressure modulator valve, protect vehicle exterior from possible brake fluid spillage. NOTICE: Reposition brake pipes as necessary to remove brake pressure modulator valve. Excessive bending may cause damage to the brake pipes. Clean
5. 6. 7. 8. 9.
• Any brake fluid spillage from the brake pressure modulator valve. EBCM/EBTCM bracket and mounting bolt. Upper BPMV bracket from frame rail. EBCM/BPMV assembly from vehicle. Four EBCM/EBTCM to BPMV bolts. Separate EBCM/EBTCM from BPMV by pulling rearward until separated.
CAUTION: Do not pry EBCM/EBTCM. Be careful not to damage seal (if reusing module). If seal is damaged during removal, repair damaged area using GM P/N 123456739 silicone sealer or replace EBCM/EBTCM. Install or Connect NOTICE: See “Notice” on page 5E2-l of this section.
1. EBCM/EBTCM to BPMV. Clean • EBCM/EBTCM seal and BPMV gasket surface with alcohol. Tighten • Four mounting bolts to 4.5 N.m (40 lb. in.). • Center bolt with bracket to 14 N.m (10 lb. ft.). 2. BPMV bracket to BPMV. • If a new brake BPMV is being installed, remove shipping plugs from valve openings. CAUTION: Make sure brake pipes are correctly connected to brake pressure modulator valve. If brake pipes are switched by mistake, wheel lockup will occur and personal injury may result. The only two ways this condition can be detected are by using the Tech 1 Diagnostic Teeter or by doing an antilock stop. 3. EBCM/BPMV assembly into vehicle. Tighten • Frame rail bracket bolts to 12 N.m (106 lb. in.). 4. Brake pipe fittings. ! Important • Use locations noted during removal. Tighten • Brake pipe fittings at Brake Pressure Modulator Valve to 18 N.m (13 lb. ft.). 5. EBCM/EBTCM harness connector and motor ground cable connector. • Lock Tab. 6.Air cleaner assembly and PCM cover. Refer to Section 6C. 7.Battery negative cable, refer to Section 6D1. 8.Fill and bleed hydraulic brake system. Refer to “Bleed Procedure” in Section 5. 9.Perform “Auto Bleed Procedure” located in this section. 10. Perform “ABS/TCS Functional Check.” Refer to “Diagnosis” in this section. ELECTRONIC BRAKE (and TRACTION) CONTROL MODULE (EBCM/EBTCM) Figure 5 NOTICE: To prevent equipment damage, never connect or disconnect the wiring harness from the EBCM/EBTCM with the ignition switch in the “RUN” position.
5E2-105 ABS/TCS
1
2
3 8 5
6
4
9
9
7
5
10 11
10
ABS ONLY
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
EBTCM BPMV EBTCM TO BPMV SCREWS (4) EBTCM/BPMV ASSEMBLY BRACKET MOUNTING BOLTS FRONT BPMV MOUNTING BRACKET REAR BPMV MOUNTING BRACKET BPMV TO CHASSIS MOUNTING BOLTS CHASSIS MOUNTS BRAKE PIPES (TO WHEELS) BRAKE PIPES (TO MASTER CYLINDER)
11
ABS/TCS
Figure 5 – EBTCM/BPMV Assembly Removal
ABS/TCS 5E2-106 ! Important • The EBCM/EBTCM cannot be repaired. If faulty, it must be replaced as an assembly.
TCS ON/OFF SWITCH The traction control switch is located in the instrument panel, refer to SECTION SC for replacement
Remove or Disconnect 1. Disconnect negative battery cable, refer to Section 6D1. 2. Air cleaner assembly and PCM cover. Refer to Section 6C. 3. EBCM/EBTCM harness connector and motor ground cable connector. 4. EBCM/EBTCM bracket from vehicle. 5. Four EBCM/EBTCM to BPMV bolts. 6. EBCM/EBTCM, by pulling rearward until internal connector disengages (Do Not Twist). CAUTION: Do not pry EBCM/EBTCM. Be careful not to damage seal (If reusing module). If seal is damaged during removal, repair damaged area using GM P/N 123456739 silicone sealer or replace EBCM/EBTCM. Install or Connect NOTICE:
See ‘Notice” on page 5E2-l of this section.
! Important When replacing the EBCM/EBTCM, MAGNASTEER must be recalibrated for any of the following option combinations. 1. ABS/MAGNASTEER 2. ABS/TCS 3. ABS/TCS/MAGNASTEER 1. EBCM/EBTCM to BPMV. Clean • EBCM/EBTCM seal and BPMV gasket surface with alcohol. Tighten • Four EBCM/EBTCM to BPMV bolts to 4.5 N.m (40 lb. in.). 2. EBCM/EBTCM bracket. Tighten • EBCM/EBTCM center bracket mounting bolt to 14 N.m (10 lb. ft.). 3. EBCMIEBTCM harness connector and motor ground cable connector. • Lock Tab. 4. Air cleaner assembly and PCM cover. Refer to Section 6C. 5. Negative battery cable, refer to Section 6D1. 6. Recalibrate MAGNASTEER calibration (if equipped). See MAGNASTEER statement above. 7. Perform ABS/TCS Functional Check.
ELECTRONIC BRAKE LAMP DRIVER MODULE (LDM) Figure 6 The internal circuit board is replaceable. The terminals and housing are pint of the wiring harness. Remove or Disconnect 1. Instrument panel compartment. Refer to Section SC. 2. Unsnap LDM from mall bracket 3. Open LDM endcap and remove circuit board by pulling straight out Install or Connect 1. Circuit board into LDM case and close endcap. Use care not to damage circuit board. 2. Snap LDM into mall bracket clip. 3. Instrument panel compartment. Refer to Section SC. WHEEL SPEED SENSORS All wheel speed sensors consist of a permanent magnet and coil, which generate a small AC voltage due to magnetic induction caused by a toothed sensor ring passing near the sensor face at a specified gap. The sensor gap is not adjustable. Left and right front wheel speed sensors are not interchangeable. Left and right rear sensors are interchangeable. Front Wheel Speed Sensors Figure 7 Tool Required: J 38764-lA (Front Wheel Speed Sensor Installer) Remove or Disconnect 1. Wheel speed sensor connector. 2. Hub and bearing assembly, refer to SECTION 3C. Clean • All dirt and debris from sensor housing/sensor interface area. 3. Gently pry off wheel speed sensor slinger. Discard used slinger. 4. Sensor, gently pry off of bearing assembly.
5E2-107 ABS/TCS
ELECTRONIC BRAKE LAMP DRIVER MODULE (LDM)
Figure 6 – Electronic Brake Lamp Driver Module (LDM) ! Important • Do not allow debris to enter bearing when sensor is removed. • Do not add lubricant to bearing through sensor housing opening. The bearing is lubricated for the life of the vehicle. • Do not clean grease from toothed sensor ring. Grease does not affect sensor operation. • Inspect bearing and sensor cap far any indication of water or debris entry (i.e. rust, grease being very fluid). If indication of water or debris exists, replace entire hub and bearing assembly.
1
2
3
Clean
4
• Sealant from outer diameter of bearing hub using only a clean, lint free cloth. Install or Connect 1. Apply 620 Loctite® to groove in outer diameter of bearing hub per instructions in the service kit. 2. Sensor, using tool J 38764-1 to press sensor into place. 3. Hub and bearing assembly, refer to SECTION 3C. 4. Wheel speed sensor connector.
WHEEL SPEED CONNECTOR WHEEL SPEED SENSOR HUB AND BEARING ASSEMBLY
Figure 7 – Front Sensor/Bearing Assembly
ABS/TCS 5E2-108
Rear Wheel Speed Sensors
Figure 8
2
Remove or Disconnect
Wheel speed sensor connector. Lower strut attaching nuts and bolts.
1
Clean
All dirt and debris from sensor housing/sensor interface area. Mounting screws. Sensor.
3 4
Important
Do not allow debris to enter bearing when sensor is removed. LOWER STRUT ATTACHING NUTS Do not add lubricant to bearing through sensor housing opening. The bearing is lubricated for the life of the vehicle. REAR WHEEL SPEED SENSOR Do not clean grease from toothed sensor ring. Grease does not affect sensorSCREW operation.
Inspect
WHEEL SPEED SENSOR CONNECTOR
Sensor ring and sensor plate for contact. When contact is found, refer to SECTION 3D to replace complete bearing. Figure 8 – Rear Strut and Wheel Speed Sensor
Install or Connect
Lubricate new sensor O-ring and install sensor to housing. Mounting screws in spiral pattern.
Rear Wheel Speed Sensor Rings
Tighten
The rear sensor ring is part of the hub bearing assembly, refer to SECTION 3D replacement when the sensor ring is damaged.
Screws to 2.8 N.m (25 lb. in.). Lower strut attaching nuts and bolts.
Tighten • Nut to 190 N.m (140 lb. ft.). Wheel speed sensor connector.
WHEEL SPEED SENSOR RINGS
Inspect • Sensor ring and sensor plate for contact. When contact is found, refer to SECTION 3D to replace complete bearing. WARNING/INDICATOR LAMPS Refer to Section 8C for warning/indicator lamp removal and replacement procedures.
Front Wheel Speed Sensor Rings . The front sensor ring is part of the drive axle, refer to SECTION 4D for replacement when the sensor ring is damaged.
5E2 ABS/TCS
