Jeep Wrangler TJ 2003 User Manual

TABLE OF CONTENTS
1.0 INTRODUCTION .........................................................1
1.1 SYSTEM COVERAGE ...............................................1
1.2 SIX-STEP TROUBLESHOOTING PROCEDURE ..........................1
2.0 IDENTIFICATION OF SYSTEM .............................................1
3.0 SYSTEM DESCRIPTION AND FUNCTIONAL OPERATION ......................1
3.1 TEVES MARK 20I SYSTEM DESCRIPTION..............................1
3.1.1 PEDAL FEEL/VEHICLE CHARACTERISTICS.....................2
3.1.2 SYSTEM COMPONENTS.....................................2
3.1.3 ABS AND BRAKE WARNING INDICATORS......................2
3.1.4 CONTROLLER ANTILOCK BRAKE (CAB) .......................2
3.1.5 HYDRAULIC CONTROL UNIT .................................3
3.1.6 RELAYS/SWITCHES.........................................3
3.1.7 SENSORS .................................................3
3.2 DIAGNOSTIC TROUBLE CODES ......................................4
3.2.1 SYSTEM INITIALIZATION ....................................4
3.2.2 DIAGNOSTIC MODE ........................................4
3.2.3 INTERMITTENT DIAGNOSTIC TROUBLE CODES ................4
3.3 AXLE LOCK........................................................4
3.3.1 GENERAL .................................................4
3.3.2 DESCRIPTION .............................................4
3.4 USING THE DRBIIIT .................................................5
3.5 DRBIIIT ERROR MESSAGES .........................................5
3.5.1 DRBIIIT DOES NOT POWER UP (BLANK SCREEN) ..............5
3.5.2 DISPLAY IS NOT VISIBLE ....................................5
4.0 DISCLAIMERS, SAFETY WARNINGS .......................................5
4.1 DISCLAIMERS......................................................5
4.2 SAFETY ...........................................................6
4.2.1 TECHNICIAN SAFETY INFORMATION..........................6
4.2.2 VEHICLE PREPARATION FOR TESTING........................6
4.2.3 SERVICING SUB-ASSEMBLIES ...............................6
4.2.4 DRBIIIT SAFETY INFORMATION ..............................6
4.3 WARNING .........................................................6
4.3.1 VEHICLE DAMAGE WARNINGS ...............................6
4.3.2 ROAD TESTING A COMPLAINT VEHICLE .......................7
4.4 DIAGNOSIS........................................................7
5.0 REQUIRED TOOLS AND EQUIPMENT ......................................7
6.0 GLOSSARY OF TERMS...................................................8
7.0 DIAGNOSTIC INFORMATION AND PROCEDURES ............................9
BRAKES (CAB)
CAB POWER FEED CIRCUIT .............................................10
CONTROLLER FAILURE .................................................13
G-SWITCH NOT PROCESSABLE ..........................................15
LEFT FRONT SENSOR CIRCUIT FAILURE ..................................19
LEFT REAR SENSOR CIRCUIT FAILURE ...................................19
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Jeep Wrangler TJ 2003 Specifications

General

Brand	Jeep
Model	Wrangler TJ 2003
Category	Automobile
Language	English

Summary

Introduction to ABS System

System Coverage

Details the scope and function of the Anti-lock Brake System (ABS).

Six-Step Troubleshooting Procedure

Outlines the standard six-step process for diagnosing ABS issues.

System Identification and Operation

System Description and Functional Operation

Comprehensive overview of ABS system components and functions.

Teves Mark 20i System Description

Specific description of the Teves Mark 20i ABS system.

Pedal Feel and Vehicle Characteristics

Describes pedal feedback and vehicle behavior during ABS operation.

System Components

Lists and briefly describes the key components of the ABS system.

ABS and Brake Warning Indicators

Explains the function and appearance of ABS and brake warning lights.

Controller Antilock Brake (CAB)

Details the Controller Antilock Brake (CAB) module.

Hydraulic Control Unit (HCU)

Information on the Hydraulic Control Unit (HCU) within the ABS.

Relays and Switches

Details regarding relays and switches used in the ABS system.

Sensors

Information on the various sensors used by the ABS system.

Diagnostic Trouble Codes (DTCs)

Explanation and listing of Diagnostic Trouble Codes (DTCs).

System Initialization

Describes the system initialization process upon vehicle startup.

Diagnostic Mode

How to enter and use the vehicle's diagnostic mode.

Intermittent Diagnostic Trouble Codes

Guidance for troubleshooting intermittent DTCs.

Axle Lock System

Operation and features of the Axle Lock system.

Using the DRBIII® Tool

Instructions for operating the DRBIII® diagnostic tool.

DRBIII® Error Messages

Troubleshooting common DRBIII® error messages.

DRBIII® Not Powering Up (Blank Screen)

Steps to resolve DRBIII® power-up or blank screen issues.

DRBIII® Display Not Visible

Troubleshooting DRBIII® display visibility problems.

Disclaimers, Safety Warnings, and Diagnosis

General Disclaimers

General disclaimers regarding manual content and updates.

Safety Information for Technicians

Essential safety guidelines for service technicians.

Vehicle Preparation for Testing

Procedures for preparing a vehicle for diagnostic testing.

Servicing Sub-Assemblies

Guidelines for servicing individual system sub-assemblies.

DRBIII® Safety Information

Specific safety instructions for using the DRBIII® tool.

Vehicle Damage Warnings

Precautions to prevent damage to vehicle components.

Road Testing a Complaint Vehicle

Procedures and considerations for road testing.

General Diagnosis Procedures

General diagnostic procedures and steps.

Required Tools, Glossary, and Diagnostics

Required Tools and Equipment

List of necessary tools and equipment for service.

Glossary of Terms

Definitions of technical terms used in the manual.

Diagnostic Information and Procedures

Detailed information and procedures for system diagnostics.

ABS (CAB) System Troubleshooting

CAB Power Feed Circuit Troubleshooting

Troubleshooting procedure for CAB Power Feed Circuit.

Controller Failure Troubleshooting

Troubleshooting procedure for Controller Failure.

G-Switch Not Processable Troubleshooting

Troubleshooting procedure for G-Switch Not Processable.

Left Front Sensor Circuit Failure

Troubleshooting procedure for Left Front Sensor Circuit Failure.

Left Rear Sensor Circuit Failure

Troubleshooting procedure for Left Rear Sensor Circuit Failure.

Right Front Sensor Circuit Failure

Troubleshooting procedure for Right Front Sensor Circuit Failure.

Right Rear Sensor Circuit Failure

Troubleshooting procedure for Right Rear Sensor Circuit Failure.

Left Front Sensor Signal Failure

Troubleshooting procedure for Left Front Sensor Signal Failure.

Left Rear Sensor Signal Failure

Troubleshooting procedure for Left Rear Sensor Signal Failure.

Right Front Sensor Signal Failure

Troubleshooting procedure for Right Front Sensor Signal Failure.

Right Rear Sensor Signal Failure

Troubleshooting procedure for Right Rear Sensor Signal Failure.

Pump Motor Not Working Properly

Troubleshooting procedure for Pump Motor Not Working Properly.

System Over Voltage

Troubleshooting procedure for System Over Voltage.

System Under Voltage

Troubleshooting procedure for System Under Voltage.

ABS Warning Indicator Always On

Troubleshooting for the ABS warning indicator staying on.

ABS Warning Indicator Inoperative

Troubleshooting for the ABS warning indicator not working.

Brake Lamp Switch Issues

Troubleshooting procedure for Brake Lamp Switch issues.

Front Axle Lock Indicator Flashing

Troubleshooting for the front axle lock indicator flashing.

No Response From Controller Antilock Brake

Troubleshooting for no response from the ABS controller.

Rear Axle Lock Indicator Flashing

Troubleshooting for the rear axle lock indicator flashing.

Rear Axle Lock Inoperative

Troubleshooting for the rear axle lock being inoperative.

Connector Pinouts and Schematic Diagrams

Axle Lock Switch (Off-Road Package) Pinout

Pinout for the Axle Lock Switch connector.

Brake Lamp Switch Pinout

Pinout for the Brake Lamp Switch connector.

Controller Antilock Brake Pinout

Pinout for the Controller Antilock Brake (CAB) connector.

Data Link Connector Pinout

Pinout for the Data Link Connector (DLC).

Front Locker Indicator Switch Pinout

Pinout for the Front Locker Indicator Switch.

Front Locker Pump Pinout

Pinout for the Front Locker Pump connector.

G-Switch (LHD) Pinout

Pinout for the G-Switch (Left Hand Drive).

Instrument Cluster C1 Pinout

Pinout for Instrument Cluster C1.

Instrument Cluster C2 Pinout

Pinout for Instrument Cluster C2.

Left Front Wheel Speed Sensor Pinout

Pinout for the Left Front Wheel Speed Sensor.

Left Rear Wheel Speed Sensor Pinout

Pinout for the Left Rear Wheel Speed Sensor.

Power Distribution Center (PDC) Pinout

Pinout diagram for the Power Distribution Center (PDC).

Front Locker Relay Pinout

Pinout for the Front Locker Relay connector.

Rear Locker Relay Pinout

Pinout for the Rear Locker Relay connector.

Rear Locker Indicator Switch Pinout

Pinout for the Rear Locker Indicator Switch.

Rear Locker Pump Pinout

Pinout for the Rear Locker Pump connector.

Right Front Wheel Speed Sensor Pinout

Pinout for the Right Front Wheel Speed Sensor.

Right Rear Wheel Speed Sensor Pinout

Pinout for the Right Rear Wheel Speed Sensor.

Schematic Diagrams Overview

Visual representations of system electrical circuits.

Teves Mark 201 Controller Antilock Brake - ABS Schematic

Schematic diagram for the Teves Mark 201 ABS Controller.

Axle Lock Schematic Diagram

Schematic diagram for the Axle Lock system.