ANTILOCK BRAKE SYSTEM

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1 SECTION 4F ANTILOCK BRAKE SYSTEM Caution: Disconnect the negative battery cabe before removing or instaing any eectrica unit or when a too or equipment coud easiy come in contact with exposed eectrica terminas. Disconnecting this cabe wi hep prevent persona injury and damage to the vehice. The ignition must aso be in LOCK uness otherwise noted. TABLE OF CONTENTS Specifications F-1 Genera Specifications F-1 Schematic and Routing Diagrams F-2 ABS F-2 ABS/ABD F-3 ABS F-4 ABS/ABD F-5 Component Locator F-6 ABS, ABS/ABD F-6 ABD System Description F-7 Sef Diagnosis F-9 ABS, ABS/ABD F-9 ABS, ABS/ABD F-11 Defect Codes F-13 Maintenance and Repair F-19 On-Vehice Service F-19 Whee Speed Sensor F-19 Hydrauic Circuit F-21 ABS F-21 ABS/ABD F-24 SPECIFICATIONS GENERAL SPECIFICATIONS ECU Hydrauic System Whee Speed Sensor Impuse Ring Appication Mode Number of Pins Operating Temperature Motor Operating Current Soenoid Coi Resistance Externa Resistance Air Gap Number of teeth Front Rear Front Rear Description ABS 5.3 ABS/ABD ~ +120 C -40 ~ +85 C Beow MAX 40A Beow MAX 45A Ω except AV, HSV Ω 1.28KΩ KΩ 1.28KΩ KΩ mm mm mm mm

2 4F-2 ANTILOCK BRAKE SYSTEM SCHEMATIC AND ROUTING DIAGRAMS 5.0W 5.0W 30A ENG 30A ABS 5.0

3 ANTILOCK BRAKE SYSTEM 4F-3 ABD ACTIVE ABS/ABD 5.0

4 4F-4 ANTILOCK BRAKE SYSTEM 5.0W 5.0W 30A 30A K2 NO.21 ABS 5.3

5 ANTILOCK BRAKE SYSTEM 4F-5 5.0W 5.0W ABS/ABD 5.3

6 4F-6 ANTILOCK BRAKE SYSTEM ABS,ABS/ABD COMPONENT LOCATOR 1 ABS Hydrauic Unit 2 ABS/ABD Hydrauic Unit 3 Diagnosis Socket 4 Front Whee Speed Sensor 5 Front Impuse Ring 6 Rear Whee Speed Sensor 7 Rear Impuse Ring 8 ABS Warning Indicator Light 9 TCS Indicator Light 10 ABS/ABD ECU

7 Genera: ABD SYSTEM DESCRIPTION ANTILOCK BRAKE SYSTEM 4F-7 The Automatic Brake Differentia Lock (ABD) is a traction system by means of brake intervention ony, avaiabe in a ow speed range (< 60kph). It workes on µ-spit roads with sidewise different friction coefficients. The spinning driven whee is braked and the drive torque can be transferred to the whee on the high- µ side. During ABD active, the ABD information amp is binking. The temperature of the brakes is cacuated by a mathematica mode and ABD is switched passive if the cacuated temperature is greater than a threshod vaue(500 C). ABD is permitted again, when the cacuated temperature is ess than 350 C. Contro Agorithm: The input signas for the contro agorithm are the fitered whee speed signas from the ABS speed processing. With the speed difference of the driven whees, the contro deviation is cacuated. If the contro deviation exceeds a certain threshod vaue, the whee with the greater sip is braked activey. The threshod vaue depends on the vehice speed: It is reduced with increasing vehice speed down to a constant vaue. Speed difference driven whees [kph] 18 ABD operation Vehice speed [kph] Pressure Moduation: Depending on the contro deviation and the whee acceeration of the spinning whee, pressure increase, hod and decrease are made. The pressure moduation is done with the conventiona contro with the vaves. ASV, USV, EV and AV according the the foowing tabe: Increase Hod Decrease ASV Open Open Open USV Cosed Cosed Cosed EV Open Cosed Cosed AV Cosed Cosed Open Speed Range: ABD is avaiabe in the speed range 60 kph. Above 60 kph vehice speed, ABD is passive. It is possibe to initiate ABD operation up to a vehice speed of 55kph.

8 4F-8 ANTILOCK BRAKE SYSTEM Temperature Mode: ABD operation is a high therma oad for the brakes. To avoid any damages at the brakes, the disk temperature is cacuated with a mathematica mode for each driven whee separatey. After ignition on, the cacuation starts with 30 C and then three different phases are evauated separatey and added: ABD operation, braking and coing phase. If the temperature is highter than 500 C, ABD is disabed for this whee. It is permitted again, if the mode has cacuated down the 350 C. Lamp Concepts: The system is equipped with an ABD information amp, which is binking during ABD operation. The activation of the EBD, ABS warning amp and the ABD info ampo is summarized in the foowing tabe: Ignition ON ABS Operation ABD Operation System faiure (EBD,ABS or ABD are not distinguished) ABD passive due to temperature mode ABS warning amp 2s on for amp check OFF OFF ON OFF ABD info amp 2s on for amp check OFF Dinking (Fashing) OFF OFF EBD warning amp 2s on for amp check EBD operation / OFF OFF ON OFF

9 ANTILOCK BRAKE SYSTEM 4F-9 SELF DIAGNOSIS ABS, ABS/ABD 5.3 Initiaization 1. Turn the ignition switch to "ON" position. 2. Using a service connector, ground the No.13 termina of diagnosis socket and No.1 ground termina for 3-4 seconds. Notice If it is over 5 seconds, initiaization wi not be performed. 3. After competing the initiaization, ABS warning amp wi be turned on unti the ignition switch is turned to "OFF" position. Output of Faut Code 1. Norma : 1 puse (norma code 01) 2. Abnorma : 1 puse (faut code) Notice If appeared initia faut code and above 2 differnt faut code, perform again initiaization. Faut code wi be output the numbers of faut code with a interva of 1 second.(turn on : 0.75 sec., turn off : 0.25 sec.) Faut Code Eimination After repairing the defect parts, eiminate the faut from ECU. 1. Ground the diagnosis No.13 termina to No.1 ground termina for over 5 seconds. 2. Turn the igniotion switch to "OFF" position. Notice If not eiminate the faut code, the code wi be maintained. Check and find the other defect parts with performing the imitiaization again, if the faut code wi be output, repair the defect parts competey.

10 4F-10 ANTILOCK BRAKE SYSTEM Diagnosis the Fash Code [Ex] Time Differences of Norma Code 01 : TW1<T<Te<TW2 Time Differences of Faut Code 15 : TW1<T<Te<TW2 Time Characteristics 1. Initiaization Tba < 5.0 sec. Tba sec. 2. Output of Faut Code TW1 = sec. TW2 = sec. T = 0.75 sec., Te 0.25 sec. 3. Eimination of Faut Code Tb1 = 5.0 sec.

11 ANTILOCK BRAKE SYSTEM 4F-11 ABS, ABS/ABD 5.0 Initiaizing 1. Set the ignition switch n ON position. 2. Connect the No.1 termina (Ground) and the No.13 (ABS) from diagnosis socket ocated in E/G room by use of service connector for 3-4 seconds and initiaize the fash code. Notice Be carefu not to connect over 5 seconds. 3. ABS indicator warning ight continuousy comes on unti the ignition switch is OFF. Dignosis Tabe 1. When the system is norma One puse (norma code 01) indicates. 2. When the system is abnorma One puse (defect code) indicates. Notice Repeat the initiaizing procedure when checking the defect code Defect code is indicated once for 1 sec (ight on : 0.75 sec, ight off : 0.25 sec). Remova the Defect Code 1. Repair the defect code and remove the memorized defect code in the ECU. 2. Connect the No. 13 termina (ABS) from diagnosis socket and No. 1 termina (ground) for over 5 seconds. 3. Set the ignition switch in the OFF position. Notice Defect code wi be memorized in ECU uness the defect code is not removed. Repeat the initiaizing procedure and check the other defects.

12 4F-12 ANTILOCK BRAKE SYSTEM Diagnosis the Fash Code [ex] Time differences of nroma code 01 : TW1<T<Te<TW2 Time differences of faut code 15 : TW1<T<Te<TW2 Time Characteristics 1. Initiaization Tba < 5.0 sec. Tba sec. 2. Output of faut code TW1 = sec. TW2 = sec. T = 0.75 sec., Te 0.25 sec. 3. Eimination of faut code Tb1 = 5.0 sec.

13 ANTILOCK BRAKE SYSTEM 4F-13 DEFECT CODES Defect Code Appication Norma Defective ECU Front/eft Whee Speed Sensor (Wire) Front/right Whee Speed Sensor (Wire) Rear/eft Whee Speed Sensor (Wire) Rear/right Whee Speed Sensor (Wire) Front/eft Whee Speed Sensor (Signa) Front/right Whee Speed Sensor (Signa) Description - Repace the ECU Check resistance of the whee speed sensor : 1.280KΩ KΩ Check wire for ground and open. Repace the sensor. Check resistance of the whee speed sensor : 1.280KΩ KΩ Check wire for ground and open. Repace the sensor. Check resistance of the whee speed sensor : 1.280KΩ KΩ Check wire for ground and open. Repace the sensor. Check resistance of the whee speed sensor : 1.280KΩ KΩ Check wire for ground and open. Repace the sensor. Check wire for ground and open. Check connection of the whee speed sensor connector and ECU side connector. Measure air gap between whee teeth and whee speed sensor and check instaation of whee tooth. (Standard air gap : mm) Check output votage of the sensor by rotating the whee 1/2-1 revoution per second and shaking sensor wire. - When measured by muti - meter (AC) : output votage > 70 mv - When measured in oscioscope : output votage 120 mv/p-p Repace the sensor. Check wire for ground and open. Check connection of the whee speed sensor. connector and ECU side connector. Measure the air gap between whee teeth and whee speed sensor and check instaation of whee tooth. (Standard air gap : mm) Check output votage of the sensor by rotating the whee 1/2-1 revoution per second and shaking sensor wire.

14 4F-14 ANTILOCK BRAKE SYSTEM Defect Code Appication Description - When measured by muti - meter (AC) : output votage > 70 mv - When measured in oscioscope : output votage 120 mv/p-p Repace the sensor. 09 Rear/eft Whee Speed Check wire for ground and open. Sensor (Signa) Check connection of the whee speed sensor connector and ECU side connector. (Standard air gap : mm) Check output votage of the sensor by rotating the whee 1/2-1 revoution per second and shaking sensor wire. - When measured by muti - meter (AC) : output votage > 70 mv - When measured in oscioscope : output votage 120 mv/p-p Repace the sensor. 10 Rear/right Whee Speed Sensor (Signa) Check wire for ground and open. Check connection of the whee speed sensor connector and ECU side connector. Measure air gap between whee teeth and whee speed sensor and check instaation of whee tooth. (Standard air gap : mm) Check output votage of the sensor by rotating the whee 1/2-1 revoution per second and shaking sensor wire. - When measured by muti - meter (AC) : output votage > 70 mv - When measured in oscioscope : output votage 120 mv/p-p Repace the sensor. 11 Whee Rotor Check number of teeth on the whee rotor and its condition. - Number of teeth : Vave Reay Check vave reay votage. Check connection of connector and terminas in the ECU and hydrauic moduator. Check ground. Check terminas for open or short. (When connector is removed) Repace the hydrauic moduator.

15 ANTILOCK BRAKE SYSTEM 4F-15 Defect Code Appication Description 13 Front / eft INLET Vave Check each vave by using SCANNER's soenoid vave overriding function. Check connection of connector and terminas in the ECU hydrauic moduator. 14 Front / eft OUTLET Vave Check each vave by using SCANNER's soenoid vave overriding function. Check connection of connector and terminas in the ECU hydrauic moduator. Check terminas for open or short. (When connector is removed) Repace the hydrauic moduator. 15 Front / right INLET Vave Check each vave by using SCANNER's soenoid vave overriding function. Check connection of connector and terminas in the ECU hydrauic moduator. Check terminas for open or short. (When connector is removed) Repace the hydrauic moduator. 16 Front / right OUTLET Vave Check each vave by using SCANNER's soenoid vave overriding function. Check connection of connector and terminas in the ECU hydrauic moduator. Check terminas for open or short. (When connector is removed) Repace the hydrauic moduator. 17 Rear / eft INLET Vave (ABD) Check each vave by using SCANNER's soenoid vave overriding function. Check connection of connector and terminas in the ECU hydrauic moduator. Check terminas for open or short. (When connector is removed) Repace the hydrauic moduator. 18 Rear / eft OUTLET Vave Check each vave by using SCANNER's soenoid vave overriding function. Check connection of connector and terminas in the ECU hydrauic moduator. Check terminas for open or short. (When connector is removed) Repace the hydrauic moduator. 19 Rear / Right INLET Vave Check each vave by using SCANNER's soenoid vave overriding function. Check connection of connector and terminas in the ECU hydrauic moduator. Check terminas for open or short.

16 4F-16 ANTILOCK BRAKE SYSTEM Defect Code Appication Description Check terminas for open or short. (When connector is removed) Repace the hydrauic moduator. 20 Rear / Right OUTLET Vave Check each vave by using SCANNER's soenoid vave overriding function. Check connection of connector and terminas in the ECU hydrauic moduator. Check terminas for open or short. (When connector is removed) Repace the hydrauic moduator 21 Function and Response of The Vave Check soenoid interna resistance of the prime(asv) vave and piot vave(usv) : Ω Check each vave by using SCANNER's soenoid vave overriding function. Check connection of connector and terminas in the ECU and hydrauic moduator. Check terminas for open or short. (When connector is removed) Repace the hydrauic moduator 22 Function and Response of The Vave Check soenoid interna resistance of the prime(asv) vave and piot vave(usv) : Ω Check each vave by using SCANNER's soenoid vave overriding function. Check connection of connector and terminas in the ECU and hydrauic moduator. Check terminas for open or short. (When connector is removed) Repace the hydrauic moduator 24 Motor Reay / Circuation Pump Check each vave by using SCANNER's pump motor overriding function. Check resistance between pump motor ground termina and battery negative termina : tota resistance shoud be ess than 15 mω Check body ground ocation. Check reay suppy votage : IGN on : V Reay coi interna resistance : Ω Repace the hydrauic moduator 27 Stop Lamp Switch Check by using SCANNER's stop amp switch diagnosing function from sensor vaue output function. Check connection of ECU connector side stop amp switch termina. Check resistance of the stop amp, switch. - Each end resistance vaue of the switch

17 Defect Code Appication Power Votage Residua Temperature Measurement (ABD ony) Acceeration Sensor Signa (wire) ANTILOCK BRAKE SYSTEM 4F-17 Description when switch knob (panger) is pressed by 3mm : - Each ends resistance vaue of the switch when switch knob(punger) is not pressed : ess than 200 mω When brake is appied : ECU (ABS:No.14, ABD:No.48) termina V or VBattery. When brake is reeased : ECU (ABS:No.14, ABD:No.48) termina 0 V Check battery votage. Resistance between ECU (ABD:No.28 & 29, ABS:No.19) pins and battery negative termina : ess than 20 mω Resistance between ECU No.1 (ABS:NO.15) pin and ignition termina : ess than 60 mω Check that norma votage is appied to ECU (ABD:No.1, ABS:No.15) pin when ignition switch is turned to "ON" or "OFF". Check ABS fuses of 15A and 80A. Repace the ECU. Check wire (ECU No.50) for open or oose contact. Check connection between connectors. Check reevant wires for open or short. (When connector is removed) Check votage between ECU side ground (ABD:No.1, ABS:No.15 pin) and acceeration sensor side ground (ABD:No.1, ABS:No.15 pin / ECU side ABD:No.39, ABS:No.30 pin) (When connector is instaed and power is appied) - Votage : ess than 0.25 V Check votage among reated terminas. (When connector is instaed and power is appied) - Votage between ECU (ABD:No.43, ABS:No.28 pin and ABD:No.39, ABS:No.30 pin) : V - Signa votage between ECU (ABD:No.51, ABS:No.10) pin and (ABD:No.39, ABS:No.30) pin : 1.95 V V (Measure it by aying acceeration sensor horizontay and without externa force)

18 4F-18 ANTILOCK BRAKE SYSTEM Defect Code Appication 43 Acceeration Sensor Signa (Signa) Description Check connection between connectors. Check reevant wires for open or short. (When connector is removed) Check and repace the acceeration sensor. Repace the ECU. Check votage between ECU side ground (ABD:No.1, ABS:No.15 pin) and acceeration sensor side ground (ABD:No.1, ABS:No.15 pin / ECU side ABD:No.39, ABS:No.30 pin) (When connector is instaed and power is appied) - Votage : ess than 0.25 V Check votage among reated terminas. (When connector is instaed and power is appied) - Votage between ECU (ABD:No.51, ABS:No.10 pin and ABD:No39, ABS:No.30) pin : V - Signa votage between ECU (ABD:No.51, ABS:No.10 pin and ABD:No39, ABS:No.30) pin : 1.95 V V (Measure it by aying acceeration sensor horizon tay and without externa force)

19 WHEEL SPEED SENSOR MAINTENANCE AND REPAIR ON-VEHICLE SERVICE ANTILOCK BRAKE SYSTEM 4F-19 1 Bot 2 Front Whee Speed Sensor 3 Knucke 4 Bot 5 Rear Whee Speed Sensor 6 Rear Axe

20 4F-20 ANTILOCK BRAKE SYSTEM Remova & Instaation Procedure ABS Hydrauic Unit 1. Reease the ABS wiring connector ocking ever in arrow direction and remove the connector. Notice Do not force the connector when reeasing in arrow direction. For instaation of the connetor, aign and firmy seat the connector of the hydrauic unit and wiring connector whie keeping the ocking ever upward and then push it down. 2. Remove the hydrauic ines of the hydrauic unit. During remova, be carefu not to drip brake fuid on the body. Instaation Notice Tightening Torque Nm 3. Unscrew hydrauic unit mounting nuts (2EA) and remove the unit from the bracket. Instaation Notice Tightening Torque 9-12 Nm Notice When carrying a new unit, never recine it over 30. Remova of the ABS / ABD Unit Location : Under the front passenger's seat. 1. Remove the wiring connector of the ABS/ABD(or ABS:attached type) ECU. 2. Remove the ground wire. 3. Unscrew the mounting bots and remove the ECU. 4. Instaation shoud foow the remova precedure in reverse order.

21 ABS 5.3 Pressure Increased HYDRAULIC CIRCUIT ANTILOCK BRAKE SYSTEM 4F-21 1 Master Cyinder 2 Hydrauic Unit 3 Damping Chamber 4 Return Pump 5 Return Pump Motor 6 Accumuator Chamber 7 Inet Vave for Each Whee 8 Outet Vave for Each Whee 9 Front Whee 10 Rear Whee

22 4F-22 ANTILOCK BRAKE SYSTEM Pressure Decreased 1 Master Cyinder 2 Hydrauic Unit 3 Damping Chamber 4 Return Pump 5 Return Pump Motor 6 Accumuator Chamber 7 Inet Vave for Each Whee 8 Outet Vave for Each Whee 9 Front Whee 10 Rear Whee

23 ANTILOCK BRAKE SYSTEM 4F-23 Pressure Maintained 1 Master Cyinder 2 Hydrauic Unit 3 Damping Chamber 4 Return Pump 5 Return Pump Motor 6 Accumuator Chamber 7 Inet Vave for Each Whee 8 Outet Vave for Each Whee 9 Front Whee 10 Rear Whee

24 4F-24 ANTILOCK BRAKE SYSTEM ABS/ABD 5.3 Pressure Increased 1 Master Cyinder 2 Hydrauic Unit 3 Damping Chamber 4 Return Pump 5 Return Pump Motor 6 Accumuator Chamber 7 Inet Vave for Each Whee 8 Outet Vave for Each Whee 9 Whee 10 Prime Vave (ASV) 11 Piot Vave (USV) 12 Check Vave 13 ISD (Integrated Suction Damper)

25 ANTILOCK BRAKE SYSTEM 4F-25 Pressure Decreased 1 Master Cyinder 2 Hydrauic Unit 3 Damping Chamber 4 Return Pump 5 Return Pump Motor 6 Accumuator Chamber 7 Inet Vave for Each Whee 8 Outet Vave for Each Whee 9 Whee 10 Prime Vave (ASV) 11 Piot Vave (USV) 12 Check Vave 13 ISD (Integrated Suction Damper)

26 4F-26 ANTILOCK BRAKE SYSTEM Pressure Maintained (Hod) 1 Master Cyinder 2 Hydrauic Unit 3 Damping Chamber 4 Return Pump 5 Return Pump Motor 6 Accumuator Chamber 7 Inet Vave for Each Whee 8 Outet Vave for Each Whee 9 Whee 10 Prime Vave (ASV) 11 Piot Vave (USV) 12 Check Vave 13 ISD (Integrated Suction Damper)

USER INSTRUCTIONS USER INSTRUCTIONS. Innovative Car Alarm. Thatcham M.I.R.R.C. Evaluation No: TC2-1065/0199

USER INSTRUCTIONS USER INSTRUCTIONS Innovative Car Aarm Thatcham M.I.R.R.C. Evauation No: TC2-1065/0199 IMPORTANT WARNING The Cobra 7928/26/HF Aarm Immobiiser is a Category 1 MIRRC Thatcham isted security