2003 Town Car Workshop Manual

Transcription

1 Page 1 of 12 SECTION : Brake System General Information 2003 Town Car Workshop Manual DIAGNOSIS AND TESTING Procedure revision date: 06/02/2006 Brake System Printable View (303 KB) Special Tool(s) Worldwide Diagnostic System (WDS) Vehicle Communication Module (VCM) with appropriate adapters, or equivalent diagnostic tool 73III Automotive Meter 105-R0057 or equivalent On-Car Brake Lathe or equivalent Material Item High Performance DOT 3 Motor Vehicle Brake Fluid PM-1 (Canada CPM-1) Silicone Brake Caliper Grease and Dielectric Compound XG-3 Brake Parts Cleaner PM-4 Specification ESA-M6C25-A ESE-M1C171-A Inspection and Verification WARNING: Use of any brake fluid other than the approved DOT 3 will cause permanent damage to brake components and will render the brakes inoperative. Failure to follow these instructions may result in personal injury. WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. In the USA or Canada on Ford/Motorcraft products call: For additional information, consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in personal injury. CAUTION: Do not spill brake fluid onto painted surfaces. If spilled, wipe up immediately. NOTE: Always check the fluid level in the brake master cylinder reservoir before carrying out the test procedures. If the fluid level is not at the correct level, clean the reservoir cap before removing, then add DOT 3 motor vehicle brake fluid. NOTE: Prior to carrying out any diagnosis, make sure the red brake warning indicator is functional. For additional information, refer to Section The first indication that something may be wrong in the brake system is a change in the feeling through the brake pedal. The brake warning indicator in the instrument cluster and the brake fluid level in the brake master cylinder reservoir are also indicators of system concerns. If a wheel is locked and the vehicle must be moved, open a bleeder screw at the locked wheel to let out enough fluid to relieve the pressure. Close the bleeder screw. This bleeding operation may release the brakes but will not correct the cause of the trouble. If this does not relieve the locked wheel condition, repair the locked components before proceeding. Inspect all hoses and connections. All unused vacuum connectors should be capped. Make sure hoses and their connections are correctly secured and in good condition with no holes, soft or collapsed areas. Road Test The technician should have a thorough knowledge of the brake system operation and accepted general braking guidelines in order to detect any problems. Select a road that is reasonably smooth and level. Gravel or bumpy roads are not suitable because the surface does not allow the tires to grip the road equally. Avoid crowned roads. A key factor in evaluating brake concerns is the deceleration rate. This varies from vehicle to vehicle and with changes in operating conditions. It is evident how well the brakes are working after just a few applications. Visual Inspection Chart Mechanical Brake master cylinder Brake caliper piston Brake discs Brake pads Power brake booster Brake pedal linkage Vacuum booster hose Tires Electrical Central junction box (CJB) fuse 14 (15A) Battery junction box (BJB) fuse 103 (50A) Parking brake switch Damaged or corroded wiring harness Brake master cylinder fluid level switch Adjustable pedal switch Adjustable pedal motor Connectors fully engaged

2 Page 2 of 12 Foreign material For low or spongy brake pedal concerns: check and, if necessary, refill the brake master cylinder reservoir. bleed the brake system and retest the brake pedal feel. check the brake pedal mounting for looseness and correct installation if the brake pedal is still low or feels spongy. Check the power brake booster and the brake master cylinder for loose mounting. Correct as necessary and retest the system for normal operation. For a slow or incomplete brake pedal return concern: inspect for binding, damage, correct installation or interference at the brake pedal. check the power brake booster for binding, damage and correct installation. Brake Pads NOTE: It is not required to install new brake pads if friction material properties are within guidelines. It is also not required to install new brake pads when the brake discs are machined. Remove the brake pads. For additional information, refer to Section for front disc brakes or Section for rear disc brakes. Inspect and measure the thickness of the brake pad friction material. Install new brake pads if the thickness of the friction material is less than 3.0mm (0.118 inch). For additional information, refer to Section for front disc brakes or Section for rear disc brakes. Compare all four front or rear pads for uneven wear. Install new brake pads if the thickness of the friction material varies from pad to pad by more than 2.0mm (0.079 inch). For additional information, refer to Section for front disc brakes or Section for rear disc brakes. Install new brake pads if there are missing chunks or cracks in the lining through to the backing plate. For additional information, refer to Section for front disc brakes or Section for rear disc brakes. If the friction material shows taper wear (i.e. the thickness varies by more than 3.0mm [0.118 inch] in any direction) verify the caliper guide pins are functioning correctly. For additional information, refer to Brake Caliper Guide Pins in this section. Brake Discs CAUTION: Using an impact tool without a torque socket will lead to unevenly tightened lug nuts. This causes brake disc on-vehicle lateral runout and brake roughness. NOTE: It is generally not required to install new brake discs to address noise issues. Remove the brake disc. For additional information, refer to Section for front disc brakes or Section for rear disc brakes. Inspect the brake discs and measure the brake disc thickness in a minimum of 4 places around the circumference of the brake disc. Record the measurements. Install new brake discs if any thickness measurement is less than the minimum specification. For additional information, refer to Section for front disc brakes, or Section for rear disc brakes. Install new brake discs if cracked. For additional information, refer to Section for front disc brakes or Section for rear disc brakes. Machine the brake discs if the diagnosis has revealed vibration in the steering wheel, seat, or pedal while braking. Heavily scored brake discs, similar to that caused by pads worn down to the backing plate, should also be machined. In order to machine, discs must be above the minimum thickness to machine specification. For additional information, refer to Specifications and Brake Disc Machining in this section. Brake Caliper Inspect the brake calipers for the following: Brake fluid leaks. For additional information, refer to Brake System Leak Check in this section. Boots and seals for tears or cracks. Caliper piston for binding and corrosion. Guide pins for correct operation. For additional information, refer to Brake Caliper Guide Pins in this section. Brake Caliper Guide Pins CAUTION: Do not use power tools for caliper guide pin bore cleaning. The guide pins should slide with a reasonable amount of hand force. If the brake pads show taper wear or the guide pins are difficult to move, then carry out the following steps. NOTE: If a guide pin kit is not available, install a new caliper assembly. Disassemble the guide pins. For additional information, refer to Section for front disc brakes, or Section for rear disc brakes. Use a wire brush, rolled-up sandpaper or emery cloth to remove all corrosion and foreign material from the caliper guide pin bores. Clean remaining debris from the bores with brake parts cleaner and compressed air. Install new brake pads if the lining is not within specifications. For additional information, refer to Section for front disc brakes, or Section for rear disc brakes. Assemble the caliper guide pins using new caliper seals, boots and guide pins. Use an ample amount of grease to lubricate the bores and guide pins. Brake Lines and Tubes CAUTION: Never use copper tubing. It is subject to fatigue, cracking and corrosion, which could result in brake tube failure. Double-wall steel tubing is used throughout the brake hydraulic system. All brake tube fittings must be correctly flared to provide strong, leakproof connections. When bending tubing to fit the underbody or rear axle contours, be careful not to kink or crack the tube. If a section of the brake tube is damaged, the entire section must be installed new with a tube of the same type, size, shape and length. When installing the hydraulic brake tubing, hoses, or connectors, tighten all connections to specifications. After installation, bleed the brake system. For additional information, refer to Brake System Bleeding in this section. The wet appearance on the outer cover of rubber brake hoses is called sweating. This is a normal condition for neoprene rayon-braided hose and is not a sign of leakage or cause to install a new hose. Install a new flexible brake hose if the hose shows signs of softening, cracking or other damage.

3 Page 3 of 12 When installing a new brake hose, position the hose to avoid contact with other vehicle components. n-pressure Leaks NOTE: The wet appearance on the outer cover of rubber brake hoses is called sweating. This is a normal condition for neoprene rayon-braided hose. The sweating condition is not evidence of a brake fluid leak and will not result in a loss of pressure in the system. The only part of the brake system that could have a brake fluid loss that does not appear when the system is under pressure is the brake master cylinder reservoir under the following conditions: missing or poorly-fitted brake master cylinder filler cap punctured or otherwise damaged brake master cylinder reservoir missing or damaged brake master cylinder filler cap gasket missing, damaged or poorly-fitted sealing grommets between the brake master cylinder and the brake master cylinder reservoir The brake master cylinder reservoir grommets are not repairable and must be installed new as part of a new brake master cylinder reservoir. Brake Master Cylinder rmal Conditions The following conditions are considered normal and are not indications that the brake master cylinder is in need of service. Condition 1: During normal operation of the brake master cylinder, the fluid level in the brake master cylinder reservoir will rise during brake application and fall during release. The net fluid level (such as after brake application and release) will remain unchanged. Condition 2: A trace of brake fluid will exist on the booster shell below the master cylinder mounting flange. This results from the normal lubricating action of the master cylinder bore and seal. Condition 3: Fluid level will decrease with pad wear. Brake Master Cylinder Abnormal Conditions Changes in brake pedal feel or travel are indicators that something could be wrong in the brake system. GO to Symptom Chart for abnormal condition diagnosis. Brake Booster Inspect the brake booster for the following: excessive corrosion or damage vacuum connections for leakage vacuum hoses for kinks or leakage brake booster check valve for correct operation Changes in the brake pedal feel or travel are indicators that something could be wrong in the brake system. GO to Symptom Chart for abnormal condition diagnosis. Parking Brake Check the operation of the parking brake system with the vehicle on a hoist and the parking brake control fully released. Check for any damaged cables and install new components as necessary. Check the rear brake adjustment or carry out the brake system diagnosis. For additional information, refer to Section Symptom Chart Symptom Chart Condition Possible Sources Action The red brake warning indicator is always on Brake fluid level FILL the brake fluid reservoir to the MAX line. Red brake warning indicator inoperative Circuitry Instrument cluster Circuitry Bulb REFER to Section REFER to Section The brakes pull or drift Tire air pressure CHECK the tires for uneven or excessive wear, and correct inflation. Brake pads Brake components Suspension component Wheel alignment CHECK the brake pads for uneven taper or excessive wear. REPAIR as necessary. CHECK the brake discs and the hubs for damage. REPAIR as necessary. CHECK wheel alignment. REFER to Section Brake pedal goes down fast Brake fluid level INSPECT the system for leaks. FILL the brake master cylinder reservoir. BLEED the system. Air in system Brake master cylinder INSPECT the system for leaks. BLEED the system. REFER to Brake System Bleeding in this section. CARRY OUT the Brake Master Cylinder Component Test in this section. The brake pedal eases down slowly Air in system INSPECT the system for leaks. BLEED the system. REFER to Brake System Bleeding in this section. Brake master cylinder CARRY OUT the Brake Master Cylinder Component Test in this

4 Page 4 of 12 section. Brake lockup under light brake pedal force Brake pads CHECK the brake pads for uneven taper or excessive wear. REPAIR as necessary. Excessive/erratic brake pedal travel Brakes drag Brake component Parking brake component Anti-lock brake control system (ABS) Leak in hydraulic system Air in system Disc brake caliper Brake master cylinder Brake pads Brake pedal Parking brake component Brake caliper guide pins Disc brake caliper Brake booster Brake master cylinder CHECK the brake components for correct operation. REPAIR as necessary. REPAIR or INSTALL new components as necessary. REFER to Parking Brake in this section. CHECK the anti-lock brake control system. REFER to Section INSPECT the system for leaks. BLEED the system. REFER to Brake System Bleeding in this section. CARRY OUT the Brake Master Cylinder Component Test in this section. CHECK the brake pads for excessive wear. CHECK the brake pedal for binding or obstructions. REPAIR as necessary. REPAIR or INSTALL new components as necessary. REFER to Parking Brake in this section. REPAIR or INSTALL new caliper guide pins, seals and boots. REFER to Brake Caliper Guide Pins in this section. REPAIR or INSTALL new brake calipers as necessary. REFER to Section for front disc brakes or Section for rear disc brakes. CARRY OUT the Brake Booster Component Test in this section. CARRY OUT the Brake Master Cylinder Component Test in this section. Excessive brake pedal effort Brake booster CARRY OUT the Brake Booster Component Test in this section. Rattling noise Clicking noise with brakes applied with anti-lock brake system (ABS) brakes Squealing noise occurs on first (morning) brake application Squealing noise a continuous squeal Squealing noise an intermittent squeal brought on by cold, heat, water, mud or snow Groaning noise occurs at low speeds with brake lightly applied (creeping) Grinding noise continuous Moaning noise Vibration when the brakes are applied Brake vibration/shudder occurs when the brake pedal is released Adjustable brake pedal does not operate correctly system without memory Adjustable brake pedal does not operate correctly system with memory Adjustable brake pedal does not operate correctly does not operate using the memory set switch (memory seats operate correctly) Brake booster check valve Brake booster manifold vacuum hose Caliper mounting bolts loose Damaged or worn caliper guide pins or retainers Missing or damaged antirattle clips or springs Loose brake disc shield ABS hydraulic control unit Brake pads Brake pads or linings worn below minimum thickness Brake pads Brake pads Brake pads or linings worn below minimum thickness Brake linings contaminated with grease or oil Uneven brake pad wear Brake disc pad transfer Brake disc Suspension components Brake caliper guide pins Brake drag Switch Cable Motor Obstruction(s) Battery junction box (BJB) fuse 103 (50A) Central junction box (CJB) fuse 14 (15A) Circuitry Switch Adjustable driver seat module (DSM) Battery junction box (BJB) fuse 103 (50A) Central junction box (CJB) fuse 14 (15A) CARRY OUT the Check Valve Component Test in this section. REROUTE, REPAIR or INSTALL new components as necessary. CHECK the caliper bolts. TIGHTEN to specifications. REFER to Section for front disc brakes or Section for rear disc brakes. CHECK the caliper guide pins and retainers for lubrication and correct operation. LUBRICATE or INSTALL new components as necessary. REFER to Brake Caliper Guide Pins in this section. CHECK the brake pads for missing clips or broken springs. INSTALL new components as necessary. REFER to Section for front disc brakes or Section for rear disc brakes. TIGHTEN the brake disc shield bolts to specification. REFER to Section for front disc brakes or Section for rear disc brakes. Acceptable condition. Acceptable condition. Caused by humidity and low brake pad temperature. INSPECT brake pads for excessive wear, taper wear or uneven wear. VERIFY brake pads are within minimum specifications. REFER to Brake Pads in this section. Acceptable condition. Acceptable condition. INSPECT the brake pads, brake discs and attaching hardware for damage. VERIFY brake pads are within minimum specifications. REFER to Brake Pads in this section. INSPECT the brake pads for contamination. REPAIR or INSTALL new components as necessary. REFER to Section for front disc brakes or Section for rear disc brakes. COMPLETE the brake system inspection described in Inspection and Verification in this section. GO to Pinpoint Test A. INSPECT the brake caliper guide pins for proper operation. REFER to Brake Caliper Guide Pins in this section. INSPECT the brake pads for premature wear. REPAIR or INSTALL a new caliper as necessary. REFER to Section for front disc brakes or Section for rear disc brakes. GO to Pinpoint Test B. GO to Pinpoint Test C. GO to Pinpoint Test D.

5 Page 5 of 12 Adjustable brake pedal does not operate correctly does not operate using the remote transmitter Circuitry Switch Adjustable driver seat module (DSM) Battery junction box (BJB) fuse 103 (50A) Central junction box (CJB) fuse 14 (15A) Circuitry Switch Adjustable driver seat module (DSM) Remote transmitter REFER to Section Diagnostic Trouble Code (DTC) Index DTC Description Source Action B1987 Pedal Forward/Rearward Switch Circuit Short to Battery DSM GO to Pinpoint Test C. B1988 Pedal Position Forward Switch Circuit Short to Battery DSM GO to Pinpoint Test C. B1989 Pedal Position Rearward Potentiometer Feedback Circuit Failure DSM GO to Pinpoint Test C. B1990 Pedal Forward/Rearward Potentiometer Feedback Circuit Failure DSM GO to Pinpoint Test D. B2275 Pedal Forward/Rearward Potentiometer Feedback Circuit Short to Ground DSM GO to Pinpoint Test D. Pinpoint Tests PINPOINT TEST A: VIBRATION WHEN THE BRAKES ARE APPLIED A1 CHECK OASIS AND FOR TSBs Test Step Check the On-Line Automotive Service Information System (OASIS) and Technical Service Bulletins (TSBs) for applicable brake concerns. Is there applicable information available on OASIS or in a TSB? Result / Action to Take REFER to OASIS or the TSB. CARRY OUT any necessary repairs that are indicated by OASIS or the TSB. If the concern is still present, GO to A2. A2 ROAD TEST THE VEHICLE LIGHT BRAKING Inspect the wheels and tires. Refer to Section Road test the vehicle. Warm the brakes by slowing the vehicle from 80 to 32 km/h (50 to 20 mph) using light brake force. At highway speeds of km/h (55-60 mph), apply the brake using light pedal force. Is there a vibration/shudder felt in the steering wheel, seat or brake pedal? A3 ROAD TEST THE VEHICLE MODERATE TO HEAVY BRAKING Road test the vehicle. At highway speeds of km/h (55-60 mph), apply the brake using a moderate to heavy pedal force. Is there a vibration/shudder? GO to A2. GO to A5. GO to A3. GO to A4. A4 NORMAL ACTUATION OF THE ABS SYSTEM DIAGNOSIS During moderate to heavy braking, noise from the hydraulic control unit (HCU) and pulsation in the brake pedal can be observed. Pedal pulsation coupled with noise during heavy braking or on loose gravel, bumps, wet or snowy surfaces is acceptable and indicates correct functioning of the ABS system. Pedal pulsation or steering wheel nibble (frequency is proportioned to the vehicle speed) indicates a concern with a brake or suspension component. Is the vibration/shudder vehicle speed sensitive? A5 APPLICATION OF THE PARKING BRAKE This test is not applicable to vehicles with drum-in-hat type parking brakes. For vehicles with drum-in-hat parking brakes, proceed to the next test step. For all other vehicles, apply the parking brake to identify if the problem is in the front or rear brake. At highway speeds of km/h (55-60 mph), lightly apply the parking brake until the vehicle slows down. Release the parking brake immediately after the test. Is there a vibration/shudder? A6 CHECK THE FRONT SUSPENSION Check the front suspension. Refer to Section Are all the suspension components in satisfactory condition? A7 RESURFACE THE FRONT BRAKE DISCS CAUTION: Do not use a bench lathe to machine the brake discs. NOTE: Follow the manufacturer's instructions to machine the brake discs. After machining, make sure the brake disc meets the thickness specification. Resurface the front brake discs. Refer to Brake Disc Machining in this section. Road test the vehicle. Is the vibration/shudder present? A8 CHECK THE REAR SUSPENSION Check the rear suspension. Refer to Section Are all the suspension components in satisfactory condition? The concern is not present at this time. GO to A6. The concern is not present at this time. GO to A8. GO to A6. GO to A7. REPAIR or INSTALL new components as necessary. TEST the system for normal operation. GO to A8. The concern is not present at this time. GO to A9. REPAIR or INSTALL new components as necessary. TEST the system for normal operation.

6 Page 6 of 12 A9 RESURFACE THE REAR BRAKE DISC CAUTION: Do not use a bench lathe to machine the brake discs. NOTE: Follow the manufacturer's instructions to machine the brake discs. After machining, make sure the brake disc meets the thickness specification. Resurface the rear brake discs. Refer to Brake Disc Machining in this section. Road test the vehicle. Is the vibration/shudder present? REFER to Section to continue diagnosis of the vibration. The concern is not present at this time. PINPOINT TEST B: ADJUSTABLE BRAKE PEDAL DOES NOT OPERATE CORRECTLY SYSTEM WITHOUT MEMORY B1 CHECK MOTOR SOUND Test Step Allow two minutes for the thermal overload to reset. Operate the adjustable pedal control switch. Can the adjustable pedal motor be heard to operate? B2 CHECK MOTOR INSTALLATION Check the adjustable pedal motor for correct installation. Is the motor installation OK? GO to B2. GO to B5. GO to B3. Result / Action to Take B3 CHECK ADJUSTABLE ACCELERATOR PEDAL SYSTEM Disconnect the brake pedal-to-accelerator pedal cable. CORRECT the motor installation. TEST the system for normal operation. INSTALL a new adjustable brake pedal assembly. REFER to Section TEST the system for normal operation. GO to B4. Operate the adjustable pedal control switch. Does the adjustable brake pedal operate now? B4 INSPECT FOR FOREIGN MATERIAL Inspect the adjustable accelerator pedal assembly for foreign material causing a binding condition. Was any foreign material found? B5 CHECK CABLE Detach the adjustable pedal motor cable. Inspect the ends of the brake pedal motor cable for wear or damage. Are the cable ends OK? B6 CHECK CIRCUITS FOR SHORT TO BATTERY Disconnect: Adjustable Pedal C2089. Measure voltage at C2089 pin 1 and C2089 pin 7. REMOVE the foreign material. RETEST for normal operation. GO to B5. GO to B6. INSTALL a new accelerator pedal assembly or adjustable pedal cable (with memory only). REFER to Section TEST the system for normal operation. REPAIR the short to battery. TEST the system for normal operation. GO to B7. Is the voltage greater than 0 V at either pin? B7 CHECK POWER TO SWITCH Measure the voltage at C2089 pin 2, circuit 1567 (RD/LB). GO to B8. REPAIR circuit 1567 (RD/LB). TEST the system for normal operation.

7 Page 7 of 12 Is the voltage greater than 10 V? B8 CHECK GROUND TO SWITCH Measure resistance to ground at C2089 pin 3, circuit 57 (BK) and C2089 pin 6, circuit 57 (BK). GO to B9. REPAIR the open circuit. TEST the system for normal operation. Is the resistance less than 5 ohms at both pins? B9 TEST SWITCH Connect fused jumpers between C2089 pin 1 and C2089 pin 2; and between C2089 pin 7 and C2089 pin 3. INSTALL a new adjustable pedal switch. TEST the system for normal operation. GO to B10. Does the adjustable pedal motor run? B10 CHECK SWITCH-TO-MOTOR CIRCUITS CONTINUITY Connect: Adjustable Pedal Switch C2089. Disconnect: Adjustable Pedal Motor C2003. Measure resistance to ground at both pins of the adjustable pedal motor C2003 circuits 1494 (RD) and 1495 (WH). INSTALL a new adjustable pedal motor. TEST the system for normal operation. REPAIR the open circuit. TEST the system for normal operation. Is the resistance less than 5 ohms at both pins? PINPOINT TEST C: ADJUSTABLE BRAKE PEDAL DOES NOT OPERATE CORRECTLY SYSTEM WITH MEMORY Test Step C1 USE THE RECORDED DTCS FROM THE DSM CONTINUOUS AND ON-DEMAND SELF-TEST Use the recorded results from DSM Continuous and On-Demand Self-Test. Are any DTCs recorded? Result / Action to Take If DTC B1987, GO to C9. If DTC B1988, GO to C3. If DTC B1989, GO to C3. If DTC B1342, INSTALL a new DSM. REFER to Section REPEAT the self-test. C2 CHECK DSM FOR CORRECT ADJUSTABLE PEDAL SWITCH INPUTS MONITOR DSM PID PDL_POS GO to C2.

8 Page 8 of 12 Ignition OFF. Connect the scan tool. Ignition ON. Monitor the DSM PID PDL_SW while activating the adjustable pedal switch. Does the DSM PID PDL_SW value agree with the adjustable pedal switch position within 1 second of releasing the switch? C3 CHECK ADJUSTABLE PEDAL SWITCH Ignition OFF. Disconnect: Adjustable Pedal Switch C2089. Measure the resistance between the following pins on adjustable pedal switch C2089, component side: C2089 Pins Forward Neutral Rearward 1, 6 Less than 5 ohms Less than 5 ohms Greater than 10,000 ohms 1, 2 Greater than 10,000 ohms Greater than 10,000 ohms Less than 5 ohms 7, 3 Greater than 10,000 ohms Less than 5 ohms Less than 5 ohms 7, 2 Less than 5 ohms Greater than 10,000 ohms Greater than 10,000 ohms GO to C9. GO to C3. GO to C4. INSTALL a new adjustable pedal switch. REPEAT the self-test. CLEAR the DTCs. Do the measured resistance values agree with the expected resistance values? C4 CHECK CIRCUIT 1567 (RD/LB) FOR VOLTAGE Measure the voltage between adjustable pedal switch C2089 pin 2, circuit 1567 (RD/LB), harness side and ground. GO to C5. REPAIR circuit 1567 (RD/LB). REPEAT the self-test. Is the voltage greater than 10 volts? C5 CHECK CIRCUIT 57 (BK) FOR OPEN Measure the resistance between adjustable pedal switch C2089 pin 3, circuit 57 (BK), harness side and ground; and between adjustable pedal switch C2089 pin 6, circuit 57 (BK), harness side and ground. GO to C6. REPAIR circuit 57 (BK). REPEAT the self-test. Are the resistances less than 5 ohms? C6 CHECK CIRCUIT 1492 (RD) AND CIRCUIT 1493 (WH) FOR SHORT TO VOLTAGE Disconnect: DSM C341c. Measure the voltage between adjustable pedal switch C2089 pin 7, circuit 1493 (WH), harness side and ground; and between adjustable pedal switch C2089 pin 1, circuit 1492 (RD), harness side and ground. REPAIR circuit 1493 (WH), or circuit 1492 (RD), as necessary. REPEAT the self-test. GO to C7. Is any voltage indicated? C7 CHECK CIRCUIT 1492 (RD) AND CIRCUIT 1493 (WH) FOR SHORT TO GROUND

9 Page 9 of 12 Measure the resistance between adjustable pedal switch C2089 pin 7, circuit 1493 (WH), harness side and ground; and between adjustable pedal switch C2089 pin 1, circuit 1492 (RD), harness side and ground. GO to C8. REPAIR circuit 1493 (WH), or circuit 1492 (RD), as necessary. REPEAT the self-test. Is the resistance greater than 10,000 ohms? C8 CHECK CIRCUIT 1492 (RD) AND CIRCUIT 1493 (WH) FOR OPEN Measure the resistance between adjustable pedal switch C2089 pin 1, circuit 1493 (WH), harness side and DSM C341c pin 20, circuit 1495 (WH), harness side; and between adjustable pedal switch C2089 pin 7, circuit 1492 (RD), harness side and DSM C341c pin 18, circuit 1494 (RD), harness side. INSTALL a new DSM. REFER to Section REPEAT the self-test. REPAIR circuit 1492 (RD), or circuit 1493 (WH), as necessary. REPEAT the self-test. Are the resistances less than 5 ohms? C9 CHECK DRIVER SEAT MODULE FOR CORRECT OUTPUTS USE THE DSM ACTIVE COMMANDS PEDAL_FWD AND PEDAL_RWD. Select PARK. Trigger the DSM active command PEDAL_FWD ON, and then OFF. Trigger the DSM active command PEDAL_RWD ON, and then OFF. Do the adjustable pedals respond correctly to the corresponding active commands? C10 CHECK CIRCUIT 490 (RD) FOR VOLTAGE Ignition OFF. Disconnect: DSM C341b. Measure the voltage between DSM C341b pin 2, circuit 490 (RD), harness side and ground. INSTALL a new DSM. REFER to Section REPEAT the self-test. GO to C10. GO to C11. REPAIR circuit 490 (RD). REPEAT the self-test. Is the voltage greater than 10 volts? C11 CHECK CIRCUIT 57 (BK) FOR OPEN Measure the resistance between DSM C337 pin 1, circuit 57 (BK), harness side and ground. GO to C12. REPAIR circuit 57 (BK). REPEAT the self-test. Is the resistance less than 5 ohms? C12 CHECK CIRCUIT 1490 (LB/OG) AND CIRCUIT 1489 (LB/BK) FOR SHORT TO GROUND Ignition OFF. Disconnect: DSM C341b. Disconnect: Adjustable Pedal Motor C2003. Measure the resistance between DSM C341a pin 12, circuit 1490 (LB/OG), harness side and ground; and between DSM C341a pin 14, circuit 1489 (LB/BK), harness side and ground. GO to C13. REPAIR circuit 1490 (LB/OG), or circuit 1489 (LB/BK), as necessary. REPEAT the self-test.

10 Page 10 of 12 Is the resistance greater than 10,000 ohms? C13 CHECK CIRCUIT 1490 (LB/OG) AND CIRCUIT 1489 (LB/BK) FOR OPEN Measure the resistance between DSM C341a pin 12, circuit 1490 (LB/OG), harness side and adjustable pedal motor C2003 pin 1, circuit 1490 (LB/OG), harness side; and between DSM C341a pin 14, circuit 1489 (LB/BK), harness side and adjustable pedal motor C2003 pin 2, circuit 1489 (LB/BK), harness side. GO to C14. REPAIR circuit 1489 (LB/BK), or circuit 1490 (LB/OG), as necessary. REPEAT the self-test. Are the resistances less than 5 ohms? C14 CHECK CIRCUIT 1490 (LB/OG) AND CIRCUIT 1489 (LB/BK) FOR SHORT TO VOLTAGE Measure the voltage between DSM C341a pin 12, circuit 1490 (LB/OG), harness side and ground; and between DSM C341a pin 14, circuit 1489 (LB/BK), harness side and ground. REPAIR circuit 1489 (LB/BK), or circuit 1490 (LB/OG), as necessary. REPEAT the self-test. INSTALL a new DSM. REFER to Section REPEAT the self-test. Is any voltage indicated? PINPOINT TEST D: ADJUSTABLE BRAKE PEDAL DOES NOT OPERATE CORRECTLY DOES NOT OPERATE USING THE MEMORY SET SWITCH Test Step D1 USE THE RECORDED DTCS FROM THE DSM CONTINUOUS AND ON-DEMAND SELF-TEST Use the recorded results from DSM Continuous and On-Demand Self-Test. Are any DTCs recorded? Result / Action to Take If DTC B1987, GO to D2. If DTC B1990, GO to D2. If DTC B1991, GO to D2. If DTC B1342, INSTALL a new DSM. REFER to Section REPEAT the self-test, D2 CHECK DSM FOR CORRECT OUTPUTS MONITOR THE DSM PID PDL_POS Use the adjustable pedal switch to move the pedals to a central position. Monitor the DSM PID PDL_POS while moving the adjustable pedal switch into the FWD position, then into the RWD position. Does the PID value decrease with forward movement, and increase with rearward movement, throughout the pedal's entire travel? D3 CHECK CIRCUIT 1491 (LB/YE), CIRCUIT 958 (GY/RD), AND CIRCUIT 955 (GY) FOR SHORT TO VOLTAGE Disconnect: DSM C341a. Disconnect: Adjustable Pedal Motor Sensor C2090. Measure the voltage between adjustable pedal motor sensor C2090 pin 2, circuit 1491 (LB/YE), harness side and ground; and between adjustable pedal motor sensor C2090 pin 3, circuit 958 (GY/RD), harness side and ground; and between adjustable pedal motor sensor C2090 pin 1, circuit 955 (GY), harness side and ground. GO to D2. INSTALL a new DSM. REFER to Section REPEAT the selftest. GO to D3. REPAIR circuit 1491 (LB/YE), circuit 958 (GY/RD), or circuit 955 (GY), as necessary. REPEAT the self-test. GO to D4.

11 Page 11 of 12 Is any voltage indicated? D4 CHECK CIRCUIT 1491 (LB/YE), CIRCUIT 958 (GY/RD), AND CIRCUIT 955 (GY) FOR SHORT TO GROUND Measure the resistance between adjustable pedal motor sensor C2090 pin 2, circuit 1491 (LB/YE), harness side and ground; and between adjustable pedal motor sensor C2090 pin 3, circuit 958 (GY/RD), harness side and ground; and between adjustable pedal motor sensor C2090 pin 1, circuit 955 (GY), harness side and ground. GO to D5. REPAIR circuit 1491 (LB/YE), circuit 958 (GY/RD), or circuit 955 (GY), as necessary. REPEAT the self-test. Is the resistance greater than 10,000 ohms? D5 CHECK CIRCUIT 1491 (LB/YE), CIRCUIT 958 (GY/RD), AND CIRCUIT 955 (GY) FOR OPEN Measure the resistance between adjustable pedal motor sensor C2090 pin 2, circuit 1491 (LB/YE), harness side and DSM C341c pin 19, circuit 1491 (LB/YE), harness side; and between adjustable pedal motor sensor C2090 pin 3, circuit 958 (GY/RD), harness side and DSM C341c pin 15, circuit 958 (GY/RD), harness side; and between adjustable pedal motor sensor C2090 pin 1, circuit 955 (GY), harness side and DSM C341c pin 13, circuit 955 (GY), harness side. GO to D6. REPAIR circuit 1491 (LB/YE), circuit 958 (GY/RD), or circuit 955 (GY), as necessary. REPEAT the self-test. Are the resistances less than 5 ohms? D6 CHECK ADJUSTABLE PEDAL MOTOR Disconnect: Adjustable Pedal Motor C2003. Use a fused (10A) jumper between adjustable pedal motor C2003 pin 2, circuit 1489 (LB/BK), component side and the battery positive terminal; and between adjustable pedal motor C2003 pin 1, circuit 1490 (LB/OG), component side and battery negative terminal. INSTALL a new DSM. REFER to Section REPEAT the selftest. INSTALL a new adjustable pedal motor. REPEAT the self-test. CLEAR the DTCs. REFER to Section REPEAT the self-test. CLEAR the DTCs. Use a fused (10A) jumper between adjustable pedal motor C2003 pin 2, circuit 1489 (LB/BK), component side and the battery negative terminal; and between adjustable pedal motor C2003 pin 1, circuit 1490 (LB/OG), component side and battery positive terminal. Does the adjustable pedal motor operate first in one direction, and then in the opposite direction? Component Tests

12 Page 12 of 12 Brake Booster 1. Check the hydraulic brake system for leaks or insufficient fluid. 2. With the transmission in NEUTRAL, stop the engine and apply the parking brake control. Apply the brake pedal several times to exhaust all vacuum in the system. 3. Apply the brake pedal and hold it in the applied position. Start the engine. If the vacuum system is operating, the brake pedal will tend to move downward under constant foot pressure. If no motion is felt, the power brake booster system is not functioning. Continue with the following steps. 4. Remove the vacuum booster hose from the check valve connection. Manifold vacuum must be available at the check valve end of the vacuum booster hose with the engine at idle speed and the transmission in NEUTRAL. If the manifold vacuum is available to the power brake booster, connect the vacuum booster hose to the power brake booster check valve and repeat Steps 2 and If no downward movement of the brake pedal is felt, install a new power brake booster. 6. Operate the engine a minimum of 10 seconds at fast idle. Stop the engine, and let the vehicle stand for 10 minutes. Then apply the brake pedal with approximately 89 N (20 lb) of force. The brake pedal feel should be the same as that noted with the engine operating. If the brake pedal feels hard (no power assist), install a new power brake booster check valve and retest. If the brake pedal feels spongy, bleed the hydraulic system to remove air. Refer to Brake System Bleeding in this section. Check Valve The function of the power brake booster check valve is to allow manifold vacuum to enter the power brake booster and prevent the escape of vacuum in case manifold vacuum is lost during sustained full throttle operation. To test the function of the power brake booster check valve: Start and run the engine for at least 10 seconds. Operate the brake pedal to check for power assist. Disconnect the vacuum booster hose from the power brake booster check valve. Do not remove the power brake booster check valve from the power brake booster. There should be enough vacuum retained in the power brake booster for at least one more power-assisted brake operation. Brake Master Cylinder Bypass Condition Test 1. Disconnect the brake lines at the brake master cylinder. 2. Plug the outlet ports of the brake master cylinder. 3. Apply the brakes. If brake pedal height cannot be maintained, the brake master cylinder has an internal leak and must be rebuilt or a new master cylinder must be installed. Compensator Port Check The purpose of the compensator ports in the brake master cylinder is to supply any additional brake fluid required by the system due to brake pad wear and to allow brake fluid returning from the brake lines to the brake master cylinder to enter the brake master cylinder reservoir. The returning brake fluid will cause a slight turbulence in the brake master cylinder reservoir. Turbulence seen in the brake master cylinder reservoir upon application or release of the brake pedal is normal and shows that the compensating ports are not plugged.