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Anti-Lock Brake System (ABS) : Workshop Manual
Anti-Lock Brake System (ABS) : Workshop Manual
SECTION 5A4
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ANTI-LOCK BRAKE SYSTEM (ABS) 5A4-1
SECTION 5A4
ANTI-LOCK BRAKE SYSTEM (ABS)
Service Precaution
CAUTION: Always use the correct fastener in the proper location. When you replace a fastener, use ONLY
the exact part number for that application. ISUZU will call out those fasteners that require a replacement
after removal. ISUZU will also call out the fasteners that require thread lockers or thread sealant. UNLESS
OTHERWISE SPECIFIED, do not use supplemental coatings (Paints, greases, or other corrosion inhibitors)
on threaded fasteners or fastener joint interfaces. Generally, such coatings adversely affect the fastener
torque and the joint clamping force, and may damage the fastener. When you install fasteners, use the
correct tightening sequence and specifications. Following these instructions can help you avoid damage to
parts and systems.
CONTENTS
PAGE
Service Precaution .......................................................................................................... 5A4 -1
General Description ........................................................................................................ 5A4 -5
System Components .................................................................................................. 5A4 -6
Electronic Hydraulic Control Unit (EHCU) ................................................................ 5A4 -6
Hydraulic Unit (HU) ..................................................................................................... 5A4 -6
ABS Warning Light ..................................................................................................... 5A4 -6
Wheel Speed Sensor .................................................................................................. 5A4 -6
Normal and Anti-lock Braking.................................................................................... 5A4 -6
Brake Pedal Travel...................................................................................................... 5A4 -7
Acronyms and Abbreviations .................................................................................... 5A4 -7
General Diagnosis ........................................................................................................... 5A4 -7
General Information.................................................................................................... 5A4 -7
ABS Service Precautions ........................................................................................... 5A4 -7
Computer System Service Precautions .................................................................... 5A4 -7
General Service Precautions ..................................................................................... 5A4 -8
Note on Intermittents.................................................................................................. 5A4 -8
Test Driving ABS Complaint Vehicles....................................................................... 5A4 -8
“ABS” Warning Light.................................................................................................. 5A4 -8
Normal Operation ....................................................................................................... 5A4 -8
Basic Diagnostic Flow Chart ..................................................................................... 5A4 -9
Basic Inspection Procedure....................................................................................... 5A4 -9
5A4-2 ANTI-LOCK BRAKE SYSTEM (ABS)
Installation................................................................................................................... 5A4- 64
Rear Speed Sensor Rotor ............................................................................................... 5A4- 65
Rear Speed Sensor Rotor and Associated Parts ..................................................... 5A4- 65
Removal....................................................................................................................... 5A4- 65
Inspection and Repair ................................................................................................ 5A4- 65
Installation................................................................................................................... 5A4- 65
Special Tools ................................................................................................................... 5A4- 67
ANTI-LOCK BRAKE SYSTEM (ABS) 5A4-5
9 ABS
TO EHCU
6 DIAG
ENGINE CONTROLLER
OR TO EHCU 5
CAB EXH BRAKE CUT RELAY
4
10
TO EHCU
3 ELECTRONIC HYDRAULIC
EHCU CONTROL UNIT(EHCU)
1 HYDRAULIC UNIT(HU)
2
4
5
8
Legend
(1) Hydraulic Line (7) Load Sensing Proportioning Valve (LSPV)
(2) Electronic Line (8) Battery
(3) Electronic Hydraulic Control Unit (EHCU) (9) ABS Warning Light
(4) Front Wheel Speed Sensor (10) Brake Switch
(5) Rear Wheel Speed Sensor
(6) Diagnosis Connector
5A4-6 ANTI-LOCK BRAKE SYSTEM (ABS)
General Service Precautions case of such trouble as can be detected by the driver
The following are general precautions which should be as a vehicle symptom, however, it is necessary to give
observed when servicing and diagnosing the Anti-lock a test drive following the test procedure mentioned
Brake System and/or other vehicle systems. Failure to below, thereby reproducing the symptom for trouble
observe these precautions may result in Anti-lock diagnosis on a symptom basis:
Brake System damage. 1. Start the engine and make sure that the “ABS” W/L
• If welding work is to be performed on the vehicle goes OFF. If the W/L remains ON, it means that
using an electric arc welder, the EHCU connector the Diagnostic Trouble Code (DTC) is stored.
should be disconnected before the welding Therefore, read the code and locate the fault.
operation begins. 2. Start the vehicle and accelerate to about 30km/h
• The EHCU connector should never be connected (19 mph) or more.
or disconnected with the ignition “ON”. 3. Slowly brake and stop the vehicle completely.
• The EHCU is not separately serviceable and must 4. Then restart the vehicle and accelerate to about 40
be replaced as assemblies. Do not disassemble km/h (25 mph) or more.
any component which is designated as non- 5. Brake at a time so as to actuate the ABS and stop
serviceable in this Section. the vehicle.
• If only rear wheels are rotated using jacks or drum 6. Be cautious of abnormality during the test. If the
tester, the system will diagnose a speed sensor W/L is actuated while driving, read the DTC and
malfunction and the “ABS” warning light will locate the fault.
illuminate. But actually no trouble exists. After 7. If the abnormality is not reproduced by the test,
inspection stop the engine once and re-start it, then make best efforts to reproduce the situation
make sure that the “ABS” warning light does not reported by the customer.
illuminate. 8. If the abnormality has been detected, repair in
If the battery has been discharged accordance with the “SYMPTOM DIAGNOSIS”.
The engine may stall if the battery has been NOTE:
completely discharged and the engine is started via • Be sure to give a test drive on a wide, even road
jumper cables. This is because the Anti-lock Brake with little traffic.
System (ABS) requires a large quantity of electricity. In
• If an abnormality is detected, be sure to suspend
this case, wait until the battery is recharged, or set the
the test and start trouble diagnosis at once.
ABS to a non-operative state by removing the fuse for
the ABS. After the battery has been recharged, stop
the engine and install the ABS fuse. Start the engine
“ABS” Warning Light
again, and confirm that the ABS warning light does not When ABS trouble occurs and actuates when possible
light. the “ABS” warning light, the trouble code
corresponding to the trouble is stored in the EHCU.
Note on Intermittents Only the ordinary brake system is available when the
ABS is turned OFF. When the “ABS” warning light is
As with virtually any electronic system, it is difficult to
actuated, if the starter switch is set ON after setting it
identify an intermittent failure. In such a case
OFF once, the EHCU checks up on the entire system
duplicating the system malfunction during a test drive
and, if there is no abnormality, judges ABS to work
or a good description of vehicle behavior from the
currently and the warning light works normally even
customer may be helpful in locating a “most likely”
though the trouble code is stored.
failed component or circuit. The symptom diagnosis
chart may also be useful in isolating the failure. Most NOTE: Illumination of the “ABS” warning light indicates
intermittent problems are caused by faulty electrical that anti-lock braking is no longer available. Power
connections or wiring. When an intermittent failure is assisted braking without anti-lock control is still
encountered, check suspect circuits for: available.
• Suspected harness damage.
Normal Operation
• Poor mating of connector halves or terminals not
fully seated in the connector body (backed out). “ABS” Warning Light
• Improperly formed or damaged terminals. When the ignition is first moved from “OFF” to “ON”,
the amber “ABS” warning light will turn “ON” for 2
Test Driving ABS Complaint Vehicles seconds and will turn “OFF”.
In case that there has been an malfunction in the
lighting pattern of “ABS” warning light, the fault can be
located in accordance with the “DIAGNOSIS BY “ABS”
WARNING LIGHT ILLUMINATION PATTERN”. In
ANTI-LOCK BRAKE SYSTEM (ABS) 5A4-9
2. Ground Inspection
Step Action Yes No
1 Are ABS-related ground points ok? Go to Step 2 Repair.
Go to Step 2
2 Reconnect all components and ensure all components are Finished Go to Step 2
properly mounted.
Was this step finished?
5A4-10 ANTI-LOCK BRAKE SYSTEM (ABS)
Legend
(1) PCMCIA Card (4) DLC Cable
(2) RS 232 Loop Back Connector (5) Tech-2
(3) SAE 16/19 Adapter
ANTI-LOCK BRAKE SYSTEM (ABS) 5A4-11
2
3. Make sure the Tech 2 is powered OFF when
removing or installing the PCMCIA card.
4. The PCMCIA card has a capacity of 10 Megabytes
which is 10 times greater than the memory of the
Tech 1 Mass Storage Cartridge.
Tech
5. The Tech 2 has the capability of two snapshots.
6. The PCMCIA card is sensitive to magnetism and
Press [ENTER] to continue.
static electricity, so care should be taken in the Software Version: X.XXX
handling of the card.
7. The Tech 2 can plot a graph when replaying a
snapshot.
8. Always return to the Main Menu by pressing the NOTE: The RS232 Loop back connector is only to use
EXIT key several times before shutting down. for diagnosis of Tech 2. Refer to user guide of the
9. To clear Diagnostic Trouble Codes (DTCs), open Tech 2.
Application Menu and press “F1: Clear DTC Info”.
Getting Started
• Before operating the Isuzu PCMCIA card with the
Tech 2, the following steps must be performed:
1. The Isuzu 2000 Model Year System PCMCIA card
(1) inserts into the Tech 2 (5).
2. Connect the SAE 16/19 adapter (3) to the DLC
cable (4).
3. Connect the DLC cable to the Tech 2 (5).
4. Make sure the vehicle ignition is off.
5. Connect the Tech 2 SAE 16/19 adapter to the
vehicle DLC.
5A4-12 ANTI-LOCK BRAKE SYSTEM (ABS)
Tech
Press [ENTER] to continue.
Software Version: X.XXX
2 (N∗) ELF, NPR, NQR
(N∗ENTER)
F0: Engine
F1: Chassis
(ENTER) F2: Body
Main Menu
F0: Diagnostics
F1: Code Index
F2: View Capture Data
(F2 ENTER)
F3: Tool Options Vehicle Identification
F4: Download / Upload Help Select one of the following
Chassis
ABS
(F0)
Vehicle Identification
Select one of the following
Model Year(s) 1/2
ABS
(1) 2001
(Y) 2000
(X) 1999 (ABS/ASR ENTER)
(W) 1998
1/4
(1) 2001
(2000, ENTER)
ANTI-LOCK BRAKE SYSTEM (ABS) 5A4-13
Menu
• The following table shows which functions are used Diagnostic Trouble Codes
for the available equipment versions.
F0: Read DTC Info Ordered By Priority
Partnumer
F2: Snapshot
(F3: ENTER)
YES NO
DTC Status
Plotting Graph Flow Chart (Plotting graph after obtaining vehicle information)
5A4-16 ANTI-LOCK BRAKE SYSTEM (ABS)
Actuator Test
Actuator Test
F1: Return Pump Relay Test
F2: Front Left Solenoid Valve Test
F3: Front Right Solenoid Valve Test F0: ABS Relay Test
F4: Rear Left Solenoid Valve Test F1: Return Pump Relay Test
F5: Rear Right Solenoid Valve Test F2: Front Left Solenoid Valve Test
F6: ABS Check Light Test F3: Front Right Solenoid Valve Test
F7: Exhaust Brake Cut Test F4: Rear Left Solenoid Valve Test
F5: Rear Right Solenoid Valve Test
F6: ABS Check Light Test
ANTI-LOCK BRAKE SYSTEM (ABS) 5A4-19
Actuator Test
Dump Solenoid
F0: ABS Relay Test
F1: Return Pump Relay Test
3. Press the Hold Valve “ON” Soft Key with the brake
pedal stepped on.
4. Release the brake pedal.
5. Make sure that the Hold Valve “ON” aimed at by
Test conditions: The ignition key is the “ON” position Tech 2 and the wheel locked position are the
with the four wheels lifted up. The brake pedal is same. If different, check brake pipe, valve line
stepped on, released and stepped on again with the harness wiring and H/UNIT. Repair is needed if
parking brake released. abnormality is found.
6. Conduct Step 2 through Step 5 above on all the
Test procedure: four wheels.
1. Connect Tech 2 with the vehicle, and select
Special Function from the menus. CAUTION: When conducting this test, please
observe the following cautions.
2. Select a Hold Valve Menu from the Special
Function Menus. 1. Do not start the engine without fail.
2. Lift up the vehicle at the level floor.
• Secure a clearance from the floor surface
enough to allow the lifted tire to rotate.
Actuator Test
3. Maintain the lift up.
4. Wipe the floor surface to remove water and oil
F0: ABS Relay Test
F1: Return Pump Relay Test so that the surface may become unslippery.
5. Do not load the vehicle.
F3: Front Right Solenoid Valve Test • When lifting up the vehicle, be sure to
F4: Rear Left Solenoid Valve Test
F5: Rear Right Solenoid Valve Test observe the lifting up points. Refer to
F6: ABS Check Light Test vehicle lifting points in 0A section.
F7: Exhaust Brake Cut Test
5A4-20 ANTI-LOCK BRAKE SYSTEM (ABS)
Actuator Test
Iso Solenoid
F0: ABS Relay Test
F1: Return Pump Relay Test
EHCU Connector Pin-out Checks • Perform checks with high impedance digital
• Disconnect EHCU. multimeter 5-8840-0285-0 (J-39200) or equivalent.
0.5LG/W
CHARGE
FL-2 3 1 2
P-1
KEY SW
BATTERY J-16 J-16 J-16
50A RELAY ;
P-2
RELAY ; TAIL
0.3B
EXH.B/CUT
(ABS) SW ;
ENG.WARMING
0.3B
3W/B
0.5LG/B
0.3B 1 4 0.5BR/R
0.5B
H-7 KEY SW B-31 B-31
OFF
0.3B 0.3B
ACC
3W/B 2 B 0.5B/Y
B-67 F-12
ON 3 3B/Y
B-67 GAUGE
ST 0.5LG/B
BACK
10A METER
H-5
ABS
0.5B/Y 36 8 7
B-51 B-51
0.5B/Y
0.5B/Y
0.5LG/B
0.3W/V
0.5W
0.5B/Y
0.5B/Y
5 3 4
B-69 B-35 B-35
2
J-50 RELAY ;
SW ; EXH.BRAKE
ABS IND.
SW ; NEUTRAL
(Neutral=ON) B-35 B-35
B-69
5 2
3
0.5LG/L
J-50
0.3B
IND.LAMP ; 0.5B
1 EXH.BRAKE
0.5LG/L 0.5LG/L 1 10
B-51 B-52
0.5B/G
H-8
0.5LG/R
17
4 5
J-18 J-18 0.5BR/B
RELAY ;
EXH.BRAKE
CONTROL
0.85B
J-18 J-18
0.5LG/W
2 3
0.5LG/B
3
B-18
2B
H-5 DIODE
12 SW ; CLUTCH
0.5LG/B 1 2 0.5LG/R 1 2
B-89 B-89 B-18 B-18
0.3B 0.5B
2B
0.5B
0.85B
FRAME-LH (FRONT) B-1
8 JOINT
3B 2 7 B-29 CONNECTOR 3B 3B
HEADLIGHT BRACKET (LH) B-7
3B 3B 3B
2B 2B 2B
FRAME-LH (CENTER) J-9
ANTI-LOCK BRAKE SYSTEM (ABS) 5A4-23
0.5G
0.5G
3R
STOP STOP
LAMP LAMP
0.5LG (LH) (RH)
0.5G
EHCU ; ABS
16
J-500 STOP LAMP 22 0.5L 2
RL 12V J-500 J-78
SPEED SENSOR
3R 24 (RR,LH)
J-500 MOTOR +B 34 0.5Y 1
RL SIG J-500 J-78
3R 2
J-500 VALVE +B
32 0.5V 1
FL SIG J-500 J-75
0.5BR/R
3B 23
J-500 MOTOR GND SPEED SENSOR
(FRT,LH)
33 0.5R/B 2
3B 1 FL GRD J-500 J-75
J-500 VALVE GND
15
H-8 8
J-500 EXH.B/CUT
OUT 10 0.5P 1
FR SIG J-500 J-74
0.5LG/B 7 SPEED SENSOR
J-500 EXH.B/CUT
(FRT,RH)
0.5BR/R
IN 11 0.5L 2
FR GRD J-500 J-74
0.3W/V 35 6
H-5 J-500 IND.
0.5B/Y 3 21 0.5R 4
J-500 IG RR 12V J-500 J-78
SPEED SENSOR
12 0.5W (RR,RH)
3
H-14 MODE1 RR SIG J-500 J-78
10
0.5BR/R
29 0.3W/B 33
MODE2 J1850 J-500 H-5
2 4 0.3W/G 34 0.3W/G
MODE3 FRASH J-500 H-5
E-9
3B
ALDL
B-79
SW ; THERMO CONNECTOR
(ENG.WARM)
16 15 14 13 12 11 10 9
8 7 6 5 4 3 2 1
E-9
0.5B
0.5B
1
0.3W/B
0.5BR/B 9 0.5BR/B 16
H-14 H-8
0.5BR/B 0.5BR/B
SW ; ACCEL 3
0.5LG/W 2 1 32 0.5LG 0.5LG
B-75 B-75 H-5
0.5LG J-23
DIODE ;
FICD
1 0.5G/O A/C
J-23 COMPRESSOR
J-23
2
0.5LG
0.5L
1 1 1
J-31 J-40 J-41
0.5B
0.5B
3B 3B
3B
2B 2B 0.5B
5A4-24 ANTI-LOCK BRAKE SYSTEM (ABS)
F-10
STOP LAMP SW ; STOP LAMP
5W 10A 0.5G/Y 1 2 0.5G
B-66 B-66
FL-4
ABS
40A 3R 3R
RELAY ;
EXH.BRAKE F-14
FL-1 EXH.BRAKE
MAIN 5 2B/R 10A 0.5LG/W
60A B-38 0.5LG
8B 8W 2 5W 3W 1
H-6 B-38
H-8
RELAY; 0.5W/R 2 4 8
B-38 B-38
0.5LG/W
CHARGE
FL-2 3 1 2
P-1
KEY SW
BATTERY J-16 J-16 J-16
60A RELAY ;
P-2
TAIL
RELAY ;
0.3B
EXH.B/CUT
SW ;
(ABS)
ENG.WARMING
0.3B
3W/B
0.5LG/B
H-7 0.3B 1 4 0.5BR/B
0.5B
KEY SW B-31 B-31
OFF
0.3B
P-5
ACC
3W/B 2 B 0.5B/Y
B-67 F-12
ON 3 3B/Y
B-67 GAUGE
ST 0.5LG/B
BACK
10A METER
ABS
0.5B/Y 0.5B/Y
0.5B/Y 8 7
B-51 B-51
0.5B/Y
0.3W/V
0.5W
6 0.5B/Y
H-14 H-8 3 4
0.5B
5
0.5P
B-35 B-35
5
2
B-69
E-11 RELAY ;
ABS IND.
SW ; NEUTRAL
SW ; EXH.BRAKE
(Neutral=ON) B-35 B-35
5 2
0.3B
E-11
B-69 IND.LAMP ; 0.5B
1 EXH.BRAKE
0.5B
3
0.5LG/R 0.5LG/R 8 10
B-51 B-52
H-14 H-5
0.5BR/R
0.5LG/R
10 38
0.5B/G
4 5
A/C 0.5G/O
J-18 J-18 COMPRESSOR
RELAY ; 39
0.85B
EXH.BRAKE
CONTROL H-5
J-18 J-18
0.5BR/R
2 3
0.5LG/B
0.5LG/W
1
0.5B
17 B-18
H-8 DIODE
SW ; CLUTCH
0.5LG/B 1 2 0.5LG/R 3 2
B-89 B-89 B-18 B-18
0.3B 0.5B
2B
0.5B
0.85B
FRAME-LH (FRONT) B-1
8 JOINT
3B 2 7 B-29 CONNECTOR 3B 3B
HEADLIGHT BRACKET (LH) B-7
3B 3B 3B
2B 2B 2B
FRAME-LH (CENTER) J-9
ANTI-LOCK BRAKE SYSTEM (ABS) 5A4-25
0.5G
0.5G
3R
STOP STOP
LAMP LAMP
0.5LG (LH) (RH)
0.5G
THERMO SW ;
ENG.WARMING
RELAY ;
0.5BR 1 2
CERAMIC E-86 E-86
HEATER EHCU ; ABS
0.5BR/B
16
J-500 STOP LAMP 22 0.5L 2
RL 12V J-500 J-149
SPEED SENSOR
24 (RR,LH)
J-500 MOTOR +B 34 0.5Y 1
H-200 RL SIG J-500 J-149
2 3R 2
J-500 VALVE +B
32 0.5V 1
0.5BR/B
8
J-500 EXH.B/CUT
OUT 10 0.5P 1
FR SIG J-500 J-74
0.5LG/B 7 SPEED SENSOR
J-500 EXH.B/CUT
(FRT,RH)
11 IN 11 0.5L 2
FR GRD J-500 J-74
3B
H-8
0.3W/V 5 6
H-8 J-500 IND.
0.5B/Y 3 21 0.5R 2
J-500 IG RR 12V J-500 J-148
0.5BR/B SPEED SENSOR
0.5B/Y(NQR) 12 0.5W (RR,RH)
5 4 15 1
J-500 MODE1 RR SIG J-500 J-148
J-15 J-15
0.5B/Y(NQR) 14 29 0.3W/B 33
J-500 MODE2 J1850 J-500 H-5
0.5BR/W 18 0.5BR/W 21
H-5 B-233 QWS 16 15 14 13 12 11 10 9
SW ; ACCEL 8 7 6 5 4 3 2 1
0.5LG/W 1 2 32 0.5LG 0.5LG 14 14 0.3Y
B-75 B-75 H-5 B-233 EXH.BRAKE CHECKER B-234
0.5B
0.5B
0.5BR/R
0.5L/W 15 29 0.3L 0.3W/B
4 B-234 FICD DIAG B-234
J-23
DIODE ;
FICD
1 3 0.5L/W 37 0.5LG
J-23 J-23 H-5
J-23
2
0.5L/G
2 6
0.5LG
H-13 H-13
0.5L/G
4 1 1
EX-1 J-31 EX-3
0.5B
H-13
0.5B
0.5B
3B 3B
3B
0.5B
5A4-26 ANTI-LOCK BRAKE SYSTEM (ABS)
Connector List
ANTI-LOCK BRAKE SYSTEM (ABS) 5A4-27
Connector List
5A4-28 ANTI-LOCK BRAKE SYSTEM (ABS)
Connector List
ANTI-LOCK BRAKE SYSTEM (ABS) 5A4-29
Part Location
H-5~H-8 H-16
Chart A-1 ABS Works Frequently But Vehicle Does Not Decelerate
Step Action Yes No
1 Is braking force distribution normal between the front and Go to Step 2 Repair brake parts.
rear of the vehicle? Go to Step 6
2 Are axle parts installed normally? Go to Step 3 Repair axle parts.
Go to Step 6
3 Is there play in each wheel speed sensor? Go to Step 4 Repair wheel
speed sensor.
Go to Step 6
4 Is there damage, or powdered iron sticking to each wheel Go to Step 5 Replace sensor or
speed sensor/sensor rotor? sensor rotor.
Go to Step 6
5 Is the output of each wheel speed sensor normal? (Refer to Replace EHCU. Replace wheel
chart C-1 or TC-1) Go to Step 6 speed sensor or
repair harness.
Go to Step 6
6 Reconnect all components and ensure all components are Repeat the “Basic Go to Step 6
properly mounted. diagnostic flow
Was this step finished? chart.”
Chart TA-1 ABS Works Frequently But Vehicle Does Not Decelerate (Use TECH 2)
Step Action Yes No
1 1. Connect TECH 2. Go to Step 2 Replace wheel
2. WHEEL SENSORS make sure of the output conditions speed sensor.
of each sensor. Go to Step 3
Is the output of each sensor normal?
2 Return to Chart A-1. Go to Step 3 Go to Step 2
Was the Chart A-1 finished?
3 Reconnect all components, ensure all components are Repeat the “Basic Go to Step 3
properly mounted. diagnostic flow
Was this step finished? chart.”
ANTI-LOCK BRAKE SYSTEM (ABS) 5A4-31
Chart A-5, TA-5 Braking Sound (From Hydraulic Unit) Is Heard While Not Braking
Step Action Yes No
1 Is this the first time the vehicle is being driven after starting It is self checking Go to Step 2
the engine? sound.
Normal.
2 Is vehicle speed under 10 km/h (6 mph)? It is self checking Go to Step 3
sound.
Normal.
3 Check for the following condition: ABS may Go to Step 4
• At the time of shift down or clutch operation. sometime be
• At the time of low µ drive (ice or snow road) or rough road actuated even
drive. when brake pedal
is not applied.
• At the time of high-speed turn.
• At the time of passing curb.
• At the time of operating electrical equipment switches.
• At the time of racing the engine.
Did it occur under any one condition above?
4 Is there play in each sensor/wheel speed sensor rotor? Go to Step 5 Repair.
Go to Step 7
5 Damage or powdered iron sticking to each sensor/wheel Repair. Go to Step 6
speed sensor rotor? Go to Step 7
6 Is each sensor output normal? (Refer to chart C-1 or TC-1). Check Repair.
harness/connector Go to Step 7
for suspected
disconnection.
If no disconnection
is found, replace
EHCU.
Go to Step 7
7 Reconnect all components, ensure all components are Repeat the “Basic Go to Step 7
properly mounted. diagnostic flow
Was this step finished? chart.”
5A4-34 ANTI-LOCK BRAKE SYSTEM (ABS)
Code
Item (except
Flash Serial Diagnosis Wiring) Chart No.
out Communications
12 - Normal - -
13 C0213 Vehicle Type Error EHCU 1
14 C0214 Low Power Voltage of Rear Sensor or ECU
EHCU 2
Abnormality
15 C0215 Low Power Voltage EHCU 3
25 C0225 Exhaust Brake Cut Circuit Abnormality Relay or EHCU 4
33 C0233 Motor Drive Circuit Abnormality EHCU 5
34 C0234 Abnormal Motor Rotation EHCU 6
41 C0241 Solenoid Valve Power Supply Abnormality EHCU 7
43 C0243 Solenoid Valve Circuit Abnormality
EHCU 8
45 C0245 Solenoid Valve Circuit Abnormality
51 C0251 FL Speed Sensor Circuit Abnormality 9
52 C0252 FR Speed Sensor Circuit Abnormality 10
53 C0253 RL Speed Sensor Circuit Abnormality 11
54 C0254 RR Speed Sensor Circuit Abnormality 12
Sensor, EHCU
61 C0261 Abnormal FL Speed Sensor Signal 13
62 C0262 Abnormal FR Speed Sensor Signal 14
63 C0263 Abnormal RL Speed Sensor Signal 15
64 C0264 Abnormal RR Speed Sensor Signal 16
65 C0265 Tire Size Error Tire, Sensor, EHCU 17
* Important: DTC 20 (Reference Voltage High) cannot be indicated by Tech 2. DTC 20 can be indicated and
confirmed by flashing using Diagnosis Switch.
ANTI-LOCK BRAKE SYSTEM (ABS) 5A4-35
Diagnosis BY “ABS” Warning Light ON position or if the warning light is actuated during
Illumination Pattern driving, trouble should be diagnosed on a illumination
In the event that there is abnormality in the “ABS” pattern basis as follows:
warning light illumination pattern while the key is in the
The DLC (for Tech 2) is located behind the driver side lower cluster panel
After displaying DTC 12 three times, one DTC after The DTC 12 is displayed repeatedly. (display is
another is displayed, starting with the most recent one. discontinued after about 5 minutes)
(However, display is discontinued after about 5
minutes.)
5A4-38 ANTI-LOCK BRAKE SYSTEM (ABS)
Chart B-1-1 With the key in the ON position (Before starting the engine). Warning light
(W/L) is not activated.
Step Action Value(s) Yes No
1 Is W/L fuse F-12 disconnected? - Go to Step 5 Go to Step 2
2 Is W/L burnt out? - Go to Step 6 Go to Step 3
3 1. Turn the key off. 12V: 9.5-16.5V Go to Step 4 Go to Step 7
2. Disconnect EHCU connectors. 24V: 16.5-34V
3. Turn the key on.
4. Using DVM, measure the voltage between
J-500 EHCU connector terminals 6 and 1.
Does the DVM display a voltage within the
specified value?
4 Check the continuity between J-500 EHCU - Go to Step 9 Go to Step 8
connector terminal 1 and body ground.
Is there continuity?
5 Replace the fuse. - Go to Step 10 -
Is action complete?
6 Replace the W/L bulb. - Go to Step 10 -
Is action complete?
7 Locate and repair open circuit, poor connection - Go to Step 10 -
or short circuit in the ignition feed circuit.
Is action complete?
8 Locate and repair open circuit, poor connection - Go to Step 10 -
or short circuit in the ground circuit.
Is action complete?
9 1. Check the harness for suspected - Go to Step 10 -
disconnection.
2. If no fault found, replace the EHCU.
Is action complete?
10 1. Reconnect all components, ensure all - Go to “Basic -
components are properly mounted. diagnostic flow
2. Clear diagnostic trouble code. chart.”
Was this step finished?
5A4-40 ANTI-LOCK BRAKE SYSTEM (ABS)
Legend
(1) Battery (4) Speed Sensor
(2) DVM
(3) Resistor
ANTI-LOCK BRAKE SYSTEM (ABS) 5A4-57
Legend
(1) Battery (4) Speed Sensor
(2) DVM
(3) Resistor
Legend
(1) Brake Pipe
(2) EHCU Bracket Fix Bolt & Nut
(3) EHCU Bracket
(4) Harness Connector
(5) EHCU
Legend
(1) Speed Sensor Connector (4) Sensor Fixing Bolt
(2) Sensor Cable Fixing Bolt (5) Speed Sensor
(3) Sensor Cable Fixing Bolt (6) Front
Removal Installation
1. Remove speed sensor connector. 1. Install speed sensor and take care not to hit the
2. Remove sensor cable fixing bolts. speed sensor pole piece during installation.
3. Remove the speed sensor fixing bolt. 2. Install speed sensor fixing bolt and tighten the
4. Remove speed sensor. fixing bolt to the specified torque.
Torque: 22 N⋅⋅m (2.2kgf⋅⋅m/16lb⋅⋅ft)
3. Install speed sensor cable fixing bolts and tighten
Inspection and Repair the fixing bolt to the specified torque.
1. Check the speed sensor pole piece for presence of Torque
foreign materials; remove any dirt, etc. Bolts (2): 22 N⋅⋅m (2.2kgf⋅⋅m/16lb⋅⋅ft)
2. Check the pole piece for damage; replace speed Bolts (3): 45 N⋅⋅m (4.6kgf⋅⋅m/33lb⋅⋅ft)
sensor if necessary. NOTE: Confirm that a white or yellow line marked on
3. Check the speed sensor cable for short or open the cable is not twisted when connecting the speed
circuit, and replace with a new one if necessary. sensor cable.
To check for cable short or open, bend or stretch 4. Connect speed sensor connector.
the cable while checking for continuity.
ANTI-LOCK BRAKE SYSTEM (ABS) 5A4-61
Legend
(1) Disk Brake Assembly (6) Hub and Disc Assembly
(2) Hub Cap (7) Speed Sensor Rotor
(3) Cotter Pin (8) Inner Bearing and Outer Bearing
(4) Hub Nut (9) Oil Seal
(5) Washer (10) Spacer
Removal
1. Remove disc brake assembly and support the
caliper assembly so that the brake hose is not
stretched or damaged.
2. Remove hub cap.
3. Remove cotter pin and hub nut.
4. Remove washer.
5. Remove hub and disc assembly.
Inspection and Repair 4. Install a cotter pin through the nut and knuckle and
1. Check the speed sensor rotor for damage bend it over.
including tooth chipping, and if damaged, replace • If the notch in the nut does not line up with the
the speed sensor rotor. cotter pin hole in the knuckle, tighten the nut
until it does. Do not loosen the nut to line up a
notch and the knuckle hole.
Installation 5. Apply grease into the hub cap and install it.
1. Using a bench press, install speed sensor rotor. • 0.4N (40g/0.09lbf)
2. Install spacer onto the knuckle spindle. 6. Install the disc brake assembly and tighten two
3. Apply grease into the outer and inner bearings and bolts to the specified torque.
install bearings in the hub. • Torque: 221 N⋅⋅m (22.5kgf⋅⋅m/163lb⋅⋅ft)
4. Install oil seal into hub and disc assembly and
install hub and disc assembly on to the knuckle
spindle.
Preload Adjustment
Adjust the wheel bearing as follows:
1. Tighten the nut until you are unable to manually
rotate the hub and disc assembly.
2. Loosen the nut.
3. Attach a spring balancer to one stud. Gradually
retighten the nut until the hub and disc assembly
bearing is adjusted to the specified preload.
Legend
(1) Brake Drum (3) Speed Sensor
(2) Speed Sensor Fixing Bolt (4) Speed Sensor Bracket
5A4-64 ANTI-LOCK BRAKE SYSTEM (ABS)
Installation
1. Install speed sensor bracket and tighten the nut to
the specified torque.
Torque:
GVW Range 12,000 lbs. and 14,500 lbs. model
108 N⋅⋅m (11kgf⋅⋅m/80lb⋅⋅ft)
GVW Range 17,950 lbs. model
157 N⋅⋅m (16kgf⋅⋅m/116lb⋅⋅ft)
2. Install the speed sensor and take care not to hit
Legend the speed sensor during installation.
(1) Speed Sensor Connector 3. Install the speed sensor fixing bolt and tighten it to
the specified torque.
(2) Front
Torque: 18 N⋅⋅m (1.8kgf⋅⋅m/13lb⋅⋅ft)
(3) Speed Sensor
4. Install brake drum and tighten bolts to the specified
(4) Rear Axle torque.
Torque: 13 N⋅⋅m (1.3kgf⋅⋅m/9.5lb⋅⋅ft)
1. Disconnect speed sensor connector. 5. Connect speed sensor connector.
2. Remove brake drum. NOTE: Confirm that the harness is not twisted when
3. Remove speed sensor fixing bolt. connecting the speed sensor connector.
4. Remove speed sensor.
5. Remove speed sensor bracket.
ANTI-LOCK BRAKE SYSTEM (ABS) 5A4-65
Legend
(1) Brake Drum (6) Outer Bearing
(2) Axle Shaft (7) Rear Hub
(3) Outer Oil Seal (8) Speed Sensor Rotor
(4) Lock Washer (9) Inner Bearing
(5) Bearing Nut (10) Inner Oil Seal
5. Install hub assembly onto the axle case. 6) Rotate the hub several times to the right and
left.
7) Measure the bearing preload a second time.
6. Set the lock nut with the notched line facing out.
Preload Adjustment
1) Turn the hub to the left and right several times 8) Align the axle case groove with the closest
to establish bearing conformity. bearing nut slit.
2) Use the bearing nut wrench to tighten the NOTE: If it is difficult to align the axle case and bearing
bearing nut until the hub can not be manually nut, slightly tighten the bearing nut.
rotated. 7. Install the lock washer with the lock washer tabs
3) Loosen the bearing nut until hub rotates easily. inserted to the axle case grooves.
Install the lock bolts to prevent the bearing nut
from loosening.
Check that the lock washer tabs are inserted to the
axle case grooves.
8. Apply grease to the outer oil seal lip inner and
outer circumferences and install outer oil seal.
9. Clean the axle shaft.
Apply gear oil to the axle shaft spline.
Insert the axle shaft into the axle case.
Take care not to damage the oil seal.
10. Tighten the axle shaft nuts to the specified torque
a little at a time.
Torque: 46 N⋅⋅m (4.7kgf⋅⋅m/34lb⋅⋅ft)
11. Install brake drum.
Special Tools
ILLUSTRATION TOOL NO. TOOL NAME
5-8840-0385-0
(J-35616)
Connector test adapter kit
5-8840-0285-0
(J-39200)
High impedance multimeter
Issued by
ISUZU MOTORS LIMITED
INTERNATIONAL SERVICE DEPARTMENT
Tokyo, Japan