Anti-Lock Brake System (ABS) : Workshop Manual

WORKSHOP MANUAL
NKR . NPR . NQR
ANTI-LOCK BRAKE SYSTEM

(ABS)
SECTION 5A4
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)
Tech 2 Scan Tool ........................................................................................................ 5A4 -10

Tech 2 Features .......................................................................................................... 5A4 -11
Getting Started ............................................................................................................ 5A4 -11
Operating Procedure (For Example) ......................................................................... 5A4 -12
DTC Modes .................................................................................................................. 5A4 -13
DTC Information Mode ............................................................................................... 5A4 -13
Plotting Snapshot Graph............................................................................................ 5A4 -14
Plotting Graph Flow Chart (Plotting graph after obtaining vehicle information) .. 5A4 -15
Flow Chart for Snapshot Replay (Plotting Graph) ................................................... 5A4 -16
Tech 2 Data Display .................................................................................................... 5A4 -17
Special Function ......................................................................................................... 5A4 -17
EHCU Connector Pin-out Checks.............................................................................. 5A4 -21
Circuit Diagram ........................................................................................................... 5A4 -22
Connector List ............................................................................................................ 5A4 -30
Part Location............................................................................................................... 5A4 -33
Symptom Diagnosis ........................................................................................................ 5A4 -34
Chart A-1 ABS Works Frequently But Vehicle Does Not Decelerate...................... 5A4 -34
Chart TA-1 ABS Works Frequently But Vehicle
Does Not Decelerate (Use TECH 2) ........................................................................... 5A4 -34
Chart A-2 Uneven Braking Occurs While ABS Works ............................................. 5A4 -35
Chart A-3, TA-3 The Wheels Are Locked................................................................... 5A4 -35
Chart A-4 Brake Pedal Feed Is Abnormal ................................................................. 5A4 -36
Chart A-5, TA-5 Braking Sound (From Hydraulic Unit)
Is Heard While Not Braking........................................................................................ 5A4 -37
Symptom Diagnosis (For 2003 Year Model) ............................................................. 5A4- 38
Chart A-1 ABS Works Frequently But Vehicle Does Not Decelerate...................... 5A4- 38
Chart TA-1 ABS Works Frequently But Vehicle Does Not Decelerate
(Use TECH 2) ............................................................................................................... 5A4- 39
Chart A-2 Uneven Braking Occurs While ABS Works ............................................. 5A4- 39
Chart TA-2 Uneven Braking Occurs While ABS Works (Use TECH 2) ................... 5A4- 39
Chart A-3, TA-3 The Wheels Are Locked................................................................... 5A4- 40
Chart A-4, TA-4 Braking Sound (From Hydraulic Unit)
Is Heard While Not Braking........................................................................................ 5A4- 40
Diagnostic Trouble Codes .............................................................................................. 5A4 -41
Diagnostic Trouble Codes (For 2003 Year Model)........................................................ 5A4 -42
Diagnosis By “ABS” Warning Light Illumination Pattern ............................................ 5A4 -43
Diagnostic Trouble Codes (DTCs)............................................................................. 5A4 -43
Chart B-1-1 With the key in the ON position (Before starting the engine).
Warning light (W/L) is not activated. ......................................................................... 5A4 -47
Chart 1 (DTC 13/C0213) Vehicle Type Error.............................................................. 5A4 -48

Chart 2 (DTC 14/C0214) Low Power Voltage of
Rear Sensor or EHCU Abnormality ........................................................................... 5A4 -48
Chart 1 (DTC13/C0213) Vehicle Type Error (For 2003 Year Model) ........................ 5A4- 49
Chart 2 (DTC14/C0214) EHCU Abnormality (For 2003 Year Model) ........................ 5A4- 49
Chart 3 (DTC15/C0215) EHCU Voltage OUT of Range ............................................. 5A4- 50
Chart 3 (DTC 15/C0215) EHCU Voltage OUT of Range (For 2003 Year Model) ...... 5A4 -51
Chart 4 (DTC 25/C0225) Exhaust Brake Cut Circuit Abnormality ........................... 5A4 -52
Chart 5 (DTC 33/C0233) Motor Drive Circuit Abnormality ....................................... 5A4 -52
Chart 6 (DTC 34/C0234) Abnormal Motor Rotation .................................................. 5A4 -52
Chart 4 (DTC25/C0225) Exhaust Brake Cut Circuit Abnormality
(For 2003 Year Model)................................................................................................. 5A4- 53
Chart 5 (DTC33/C0233) Motor Drive Circuit Abnormality (For 2003 Year Model) .... 5A4- 53
Chart 6 (DTC 34/C0234) Abnormal Motor Rotation .................................................. 5A4- 53
Chart 7 (DTC 41/C0241) Solenoid Valve Power Supply Abnormality ..................... 5A4 -54
Chart 8 (DTC 43, 45/C0243, C0245) Solenoid Valve Circuit Abnormality ............... 5A4 -54
Chart 9 (DTC 51/C0251) FL Speed Sensor Circuit Abnormality .............................. 5A4 -54
Chart 10 (DTC 52/C0252) FR Speed Sensor Circuit Abnormality............................ 5A4 -54
Chart 9 (DTC51/C0251) FL Speed Sensor Circuit Abnormality
(For 2003 Year Model)................................................................................................. 5A4- 54
Chart 10 (DTC52/C0252) FR Speed Sensor Circuit Abnormality
(For 2003 Year Model)................................................................................................. 5A4- 55
Chart 11 (DTC 53/C0253) RL Speed Sensor Circuit Abnormality............................ 5A4 -55
Chart 11 (DTC 53/C0253) RL Speed Sensor Circuit Abnormality
(For 2003 Year Model)................................................................................................. 5A4 -56
Chart 12 (DTC 54/C0254) RR Speed Sensor Circuit Abnormality ........................... 5A4 -57
Chart 12 (DTC 54/C0254) RR Speed Sensor Circuit Abnormality
(For 2003 Year Model)................................................................................................. 5A4 -58
Chart 13 (DTC 61/C0261) Abnormal FL Speed Sensor Signal................................. 5A4 -59
Chart 14 (DTC 62/C0262) Abnormal FR Speed Sensor Signal ................................ 5A4 -61
Chart 15 (DTC 63/C0263) Abnormal RL Speed Sensor Signal ................................ 5A4- 63
Chart 16 (DTC 64/C0264) Abnormal RR Speed Sensor Signal................................ 5A4- 64
Chart 17 (DTC 65/C0265) Tire Size Error (Except 2003 Year Model) ...................... 5A4- 65
Unit Inspection Procedure.............................................................................................. 5A4- 66
Chart C-1-1 FL Speed Sensor Output Inspection Procedure .................................. 5A4- 66
Chart C-1-2 FR Speed Sensor Output Inspection Procedure.................................. 5A4- 67
Chart C-1-3 RL Speed Sensor Output Inspection Procedure.................................. 5A4- 68
Chart C-1-4 RR Speed Sensor Output Inspection Procedure ................................. 5A4- 70
Chart TC-1 Sensor Output Inspection Procedure (Use TECH 2) ............................ 5A4- 71
Chart TC-1 Sensor Output Inspection Procedure (Use TECH 2)

(For 2003 Year Model)................................................................................................. 5A4- 72
Electronic Hydraulic Control Unit (EHCU)..................................................................... 5A4- 73
Removal....................................................................................................................... 5A4- 73
Installation................................................................................................................... 5A4- 73
Methods of Matching and Taking off Connectors ........................................................ 5A4- 74
Before Matching.......................................................................................................... 5A4- 74
Semi Matching ............................................................................................................ 5A4- 74
Matching ...................................................................................................................... 5A4- 74
Finished Matching ...................................................................................................... 5A4- 74
Condition of matching................................................................................................ 5A4- 75
Release of lock............................................................................................................ 5A4- 75
Taking off..................................................................................................................... 5A4- 75
Finished Taking off ..................................................................................................... 5A4- 76
Front Speed Sensor ........................................................................................................ 5A4- 77
Front Speed Sensor and Associated Parts .............................................................. 5A4- 77
Removal....................................................................................................................... 5A4- 77
Inspection and Repair ................................................................................................ 5A4- 77
Installation................................................................................................................... 5A4- 77
Front Speed Sensor Rotor.............................................................................................. 5A4- 78
Front Speed Sensor Rotor and Associated Parts.................................................... 5A4- 78
Removal....................................................................................................................... 5A4- 78
Installation................................................................................................................... 5A4- 79
Rear Speed Sensor ......................................................................................................... 5A4- 80
Rear Speed Sensor and Associated Parts................................................................ 5A4- 80
Removal....................................................................................................................... 5A4- 81
Installation................................................................................................................... 5A4- 81
Rear Speed Sensor Rotor ............................................................................................... 5A4- 82
Rear Speed Sensor Rotor and Associated Parts ..................................................... 5A4- 82
Removal....................................................................................................................... 5A4- 82
Installation................................................................................................................... 5A4- 82
Special Tools ................................................................................................................... 5A4- 84
General Description determine when a wheel is about to stop turning and

The Anti-lock Brake System (ABS) works on all four adjust brake pressure to maintain best braking.
wheels. A combination of wheel speed sensor and This system helps the drive maintain greater control of
Electronic Hydraulic Control Unit (EHCU) can the vehicle under heavy braking conditions.
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
System Components ABS Warning Light

The Anti-lock Brake System consists of a Electronic
Hydraulic Control Unit (EHCU), four Wheel Speed
Sensors and Warning Light.
Electronic Hydraulic Control Unit (EHCU)

The EHCU consists of Electronic Brake Control
Module (EBCM) and Hydraulic Unit (HU).
The EHCU is located at the frame side, in front of rear
spring bracket.
The EHCU consists of ABS control circuits, fault
detector, and a fail-safe. It drives the hydraulic unit
according to the signal from each sensor, cancelling
ABS to return to normal braking when a malfunction
has occurred in the ABS.
The EHCU is self-diagnosing function which can
indicate faulty circuits during diagnosis.
Vehicles equipped with the Anti-lock Brake System

CONNECTOR has an amber “ABS” warning light in the instrument
panel. The “ABS” warning light will illuminate if a
EHCU malfunction in the Anti-lock Brake System is detected
by the Electronic Hydraulic Control Unit (EHCU). In
case of an electronic malfunction, the EHCU will turn
“ON” the “ABS” warning light and disable the Anti-lock
Tang lock braking function.
The “ABS” light will turn “ON” for 2 seconds after the
ignition switch is to the “ON” position, and then will go
Push
out.
If the “ABS” light comes “ON” and stays “ON” while
Lever driving, the Anti-lock Brake System should be
inspected for a malfunction according to the diagnosis
Move lever outside procedure.
Wheel Speed Sensor

NOTE: It consists of a sensor and a rotor. The sensor is
When disconnecting harness connector from EHCU, attached to the knuckle on the front wheels and to the
push the tang lock of the connector ( portion) and bracket on the brake back plate on the rear wheels.
release the tang lock. Then move the lever. The front speed sensor is coil type and rear is Hall IC
type.
Hydraulic Unit (HU) The sensor rotors press-fitted to front and rear wheel
It consists of a Motor, Plunger Pump, Solenoid Valves hubs output pulse frequency depending on wheel
and Check Valve. rotation.
Solenoid Valves: Reduces or holds the caliper fluid The speed sensors find vehicle speed from its
pressure for each front brake or both rear brakes frequency.
according to the signal sent from the EHCU.
Reservoir: Temporarily holds the brake fluid that Normal and Anti-lock Braking
returns from the front and rear wheel brake so that Under normal driving conditions, the Anti-lock Brake
pressure of front wheel brake can be reduced System functions the same as a standard power
smoothly. assisted brake system. However, with the detection of
Plunger Pump: Feeds the brake fluid held in the wheel lock-up, a slight bump or kick-back will be felt in
reservoir to the master cylinder. the brake pedal. This pedal “bump” will be followed by
Motor: Drives the pump according to the signal from a series of short pedal pulsations which occurs in rapid
EHCU. Check Valve: Controls the brake fluid flow. succession. The brake pedal pulsation will continue
until there is no longer a need for the anti-lock function VDC

or until the vehicle is stopped. A slight ticking or Volts DC
popping noise may be heard during brake applications VAC
when the Anti-lock features is being used.
Volts AC
When the Anti-lock feature is being used, the brake
W/L
pedal may rise even as the brakes are being applied.
Warning Light
This is also normal. Maintaining a consist force on the
pedal will provide the shortest stopping distance. WSS
Wheel Speed Sensor
Brake Pedal Travel
Vehicles equipped with the Anti-lock Brake System General Diagnosis
may be stopped by applying normal force to the brake General Information
pedal. Although there is no need to push the pedal ABS malfunction can be classified into two types,
beyond the point where it stops or holds the vehicle, by those which can be detected by the ABS warning light
applying more force the pedal will continue to travel and those which can be detected as a vehicle
toward the floor. abnormality by the driver.
This extra brake pedal travel is normal. In either case, locate the fault in accordance with the
“BASIC DIAGNOSTIC FLOWCHART” and repair.
Acronyms and Abbreviations Please refer to Section 5A for the diagnosis of
Several acronyms and abbreviations are commonly mechanical troubles such as brake noise, brake judder
used throughout this section: (brake pedal or vehicle vibration felt when braking),
ABS uneven braking, and parking brake trouble.
Anti-lock Brake System
CKT
ABS Service Precautions
Circuit Required Tools and Items:
DLC • Box Wrench
Data Link Connector • Brake Fluid
DTC • Special Tool
Diagnostic Trouble Code Some diagnosis procedures in this section require the
installation of a special tool.
DVM
5-8840-0285-0 (J-39200) High Impedance
Digital Volt Meter (High Impedance Multimeter)
Multimeter
EHCU
When circuit measurements are requested, use a
Electronic Hydraulic Control Unit circuit tester with high impedance.
FL
Front Left Computer System Service Precautions
FR The Anti-lock Brake System interfaces directly with the
Front Right Electronic Hydraulic Control Unit (EHCU) which is a
GEN control computer that is similar in some regards to the
Generator Engine Control Module. These modules are designed
to withstand normal current draws associated with
HU
vehicle operation. However, care must be taken to
Hydraulic Unit avoid overloading any of the EHCU circuits. In testing
MV for opens or shorts, do not ground or apply voltage to
Millivolts any of the circuits unless instructed to do so by the
RL appropriate diagnostic procedure. These circuits
Rear Left should only be tested with a high impedance
multimeter 5-8840-0285-0 (J-39200) or special tools
RR
as described in this section. Power should never be
Rear Right removed or applied to any control module with the
RPS ignition in the “ON” position. Before removing or
Revolution per Second connecting battery cables, fuses or connectors, always
SW turn the ignition switch to the “OFF” position.
Switch
General Service Precautions WARNING LIGHT ILLUMINATION PATTERN”. In

The following are general precautions which should be case of such trouble as can be detected by the driver
observed when servicing and diagnosing the Anti-lock as a vehicle symptom, however, it is necessary to give
Brake System and/or other vehicle systems. Failure to a test drive following the test procedure mentioned
observe these precautions may result in Anti-lock below, thereby reproducing the symptom for trouble
Brake System damage. diagnosis on a symptom basis:
• If welding work is to be performed on the vehicle 1. Start the engine and make sure that the “ABS” W/L
using an electric arc welder, the EHCU connector goes OFF. If the W/L remains ON, it means that
should be disconnected before the welding the Diagnostic Trouble Code (DTC) is stored.
operation begins. Therefore, read the code and locate the fault.
• The EHCU connector should never be connected 2. Start the vehicle and accelerate to about 30km/h
or disconnected with the ignition “ON”. (19 mph) or more.
• The EHCU is not separately serviceable and must 3. Slowly brake and stop the vehicle completely.
be replaced as assemblies. Do not disassemble 4. Then restart the vehicle and accelerate to about 40
any component which is designated as non- km/h (25 mph) or more.
serviceable in this Section. 5. Brake at a time so as to actuate the ABS and stop
• If only rear wheels are rotated using jacks or drum the vehicle.
tester, the system will diagnose a speed sensor 6. Be cautious of abnormality during the test. If the
malfunction and the “ABS” warning light will W/L is actuated while driving, read the DTC and
illuminate. But actually no trouble exists. After locate the fault.
inspection stop the engine once and re-start it, then 7. If the abnormality is not reproduced by the test,
make sure that the “ABS” warning light does not make best efforts to reproduce the situation
illuminate. reported by the customer.
If the battery has been discharged 8. If the abnormality has been detected, repair in
(except 2003 year model) 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”
Basic Diagnostic Flow Chart

Step Action Yes No
1 1. Customer complaint. Go to Step 2 Go to Step 3
2. Questioning to customer.
3. Basic inspection (Refer to “Basic inspection procedure”)
Using TECH 2?
2 Make sure of DTC by TROUBLE CODE. Go to Step 5 Go to Step 4
Is EHCU including DTC?
3 Check if the DTC is stored. Go to Step 5 Go to Step 4
Is EHCU including DTC?
4 Test drive. Go to Step 5 Trouble diagnosis
Is W/L lit? based on symptom
(Refer to
“SYMPTOM
DIAGNOSIS”) Go
to Step 5
5 1. Repair of faulty part. Repeat the Go to Step 6
2. Elimination of DTC. diagnosis of the
3. Inspection of “ABS” W/L illumination pattern with ignition symptom or DTC
SW “ON”. appears again Go
to Step 1
4. Test drive.
Does repeat trouble?
6 1. Reconnect all components and ensure all components Finished Go to Step 6
are properly mounted.
2. Clear diagnostic trouble code.
Was this step finished?
Basic Inspection Procedure

1. Basic Inspection of Service Brake
Step Action Yes No
1 Is the fluid level normal? Go to Step 2 Replenish with
fluid.
Go to Step 2
2 Does brake fluid leak from brake parts? Repair. Go to Step 3
Go to Step 3
3 Is the booster functioning normal? Go to Step 4 Repair.
Go to Step 4
4 Is the pad and rotor normal? Go to Step 5 Repair.
Go to Step 5
5 Reconnect all components and ensure all components are Finished Go to Step 5
properly mounted.
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.
Tech 2 Scan Tool

From 98 MY, Isuzu dealer service departments are
recommended to use Tech 2. Please refer to Tech 2
scan tool user guide.
Legend
(1) PCMCIA Card (4) DLC Cable
(2) RS 232 Loop Back Connector (5) Tech-2
(3) SAE 16/19 Adapter
Tech 2 Features 6. Turn on the vehicle ignition.

1. Tech 2 is a 12 volt system. Do not apply 24 volt. 7. Power the Tech 2 ON and verify the Tech 2 power
2. After connecting and/or installing the Vehicle up display.
Communications Interface (VCI) module, PCMCIA
card and DLC connector to the Tech 2, connect
the tool to the vehicle DLC.
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. (except 2003 year
Tech
model)
5. The Tech 2 has the capability of two snapshots.
Press [ENTER] to continue.
6. The PCMCIA card is sensitive to magnetism and Software Version: X.XXX
static electricity, so care should be taken in the
handling of the card.
7. The Tech 2 can plot a graph when replaying a
snapshot.
NOTE: The RS232 Loop back connector is only to use
8. Always return to the Main Menu by pressing the for diagnosis of Tech 2. Refer to user guide of the
EXIT key several times before shutting down. Tech 2.
9. To clear Diagnostic Trouble Codes (DTCs), open
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 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.
Operating Procedure (For Example)

Vehicle Identification
The power up screen is displayed when you power up Select one of the following
the tester with the Isuzu systems PCMCIA card. Follow Vehicle Type (s)
(UE) Rodeo/Amigo, Wizard/MU
the operating procedure below. (TF ) LUV
(N∗) ELF, NPR, NQR
(Off-Road) Industrial Engine
Tech
Press [ENTER] to continue.
Software Version: X.XXX
2 (N∗) ELF, NPR, NQR
(N∗ENTER)
System Selection Menu

( 1 ) 2 0 0 1 ( N∗ ) E L F , N P R , N Q R
3/4
F0: Engine
F1: Chassis
(ENTER) F2: Body
Main Menu
F0: Diagnostics
F1: Code Index
F2: View Capture Data (F2 ENTER)
F3: Tool Options
F4: Download / Upload Help Select one of the following
Chassis
ABS
(F0)
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)
(2003, ENTER)
(for 2003 year model)
Menu
• The following table shows which functions are used Diagnostic Trouble Codes
for the available equipment versions.
F0: Read DTC Info Ordered By Priority
Chassis F1: Clear DTC Information

(Y) 2000 (N∗) ELF, NPR, NQR F2: DTC Information
Electronic System: ABS
F3: Clear & Reset Vehicle Type
Partnumber 8972521653
Identifier 00(2WD)
20(4WD)
40(ABS/ASR)
60(12V vehicle)
Partnumer
Confirm The following is a brief description of each of the sub

menus in DTC Info and DTC. The order in which they
appear here is alphabetical and not necessarily the
way they will appear on the Tech 2.
DTC Modes
DTC Information Mode
Use the DTC info mode to search for a specific type of
Chassis stored DTC information. There are two choices. The
service manual may instruct the techinician to test for
DTCs in a certain manner. Always follow published
F0: Diagnostic Trouble Codes service procedures.
F1: Data Display
F2: Snapshot
F3: Actuator Test
There are two options available in Tech 2 DTC mode

to display the enhanced information available. After
selecting DTC, the following menu appears.
• DTC Info
• Clear Info
When CODE “13” is displayed (Vehicle Type Error)

Step Action Value(s) Yes No
1 Check harness. - Erase vehicle Replace the
Is it okay? type with TECH harness.
2 and reread
harness
information.
Diagnostic Trouble Codes

Clear & Reset Vehicle Type
F0: Read DTC Info
F1: Clear DTC Info
F2: DTC Info Do you want clear &

Reset Vehicle Type?
(F3: ENTER)
YES NO
YES: Clear vehicle type and reread vehicle harness

information.
NO: Return
DTC Status
Current Diagnostic Trouble Codes

This selection will display all DTCs that have failed
during the present ignition cycle.
History Diagnostic Trouble Codes

This selection will display only DTCs that are stored in
the EHCU’s history memory.
Plotting Snapshot Graph

This test selects several necessary items from the
data list to plot graphs and makes data comparison on
a long term basis. This test can check ABS
performance and defect by graphing wheel speed
differences between right and left sides, and front and
rear sides obtained from the ABS data list menu.
For trouble diagnosis, you can collect graphic data
(snap shot) directly from the vehicle.
You can replay the snapshot data as needed.
Therefore, accurate diagnosis is possible, even though
the vehicle is not available.
Plotting Graph Flow Chart (Plotting graph after obtaining vehicle information)
Flow Chart for Snapshot Replay (Plotting Graph)

Tech 2 Data Display Special Function

Use the Tech 2 data Values only after the ABS There are 12 different menus available for this test.
Diagnostic System Check has been completed, no The state of each circuit can be tested by using these
DTC(s) were noted, and you have determined that the menus. Especially when DTC cannot be detected, a
on-board diagnostics are functioning properly. Tech 2 faulty circuit can be diagnosed by testing each circuit
values from a properly-running engine may be used for by means of these menus.
comparison with the engine you are diagnosing. Even when DTC has been detected, the circuit tests
using these menus could help discriminate between a
ABS Data mechanical trouble and an electrical trouble.
Ignition SW is “ON” position. In all cases test condition; Engine stops with the key
turned to the “ON” position. To be more specific, the
(For example) test is conducted with the brake pedal stepped on after
stepping once and releasing.
• Engine: Stop
• Ignition SW: ON
• Brake Pedal: ON-OFF-ON
If the Ignition SW was turned OFF or communication
was lost, make sure to apply the brake pedal ON-OFF-
ON once again and then continue the test.
Actuator Test
F0: ABS Relay Test

F1: Return Pump Relay Test
F2: Front Left Solenoid Valve Test
F3: Front Right Solenoid Valve Test
F4: Rear Left Solenoid Valve Test
F5: Rear Right Solenoid Valve Test
F6: ABS Check Light Test
F7: Exhaust Brake Cut Test
ABS Warning Lamp ABS Motor

Test condition: Engine stops with the key turned to the Test condition: Engine stops with the key turned to the
“ON” position. To be more specific, the test is “ON” position. To be more specific, the test is
conducted with the brake pedal stepped on after conducted with the brake pedal stepped on after
stepping once and releasing. stepping once and releasing.
• The circuit is normal if the warning light in the meter Make sure of the working sound of the ABS motor.
panel comes on and goes out in accordance with The circuit is normal if the working sound of the ABS
Tech 2’s instruction. motor is made in accordance with Tech 2’s instruction.
Actuator Test Actuator Test
F0: ABS Relay Test F0: ABS Relay Test

F2: Front Left Solenoid Valve Test F2: Front Left Solenoid Valve Test
F3: Front Right Solenoid Valve Test F3: Front Right Solenoid Valve Test
F4: Rear Left Solenoid Valve Test F4: Rear Left Solenoid Valve Test
F5: Rear Right Solenoid Valve Test F5: Rear Right Solenoid Valve Test
F7: Exhaust Brake Cut Test F7: Exhaust Brake Cut Test
ABS Relay Exhaust Brake Cut Relay

Test condition: Engine stops with the key turned to the Test condition: Engine stops with the key turned to the
“ON” position. To be more specific, the test is “ON” position. To be more specific, the test is
conducted with the brake pedal stepped on after conducted with the brake pedal stepped on after
stepping once and releasing. stepping once and releasing.
Make sure of the working sound of the ABS relay. Make sure of the working sound of the exhaust brake
The circuit is normal if the working sound of the ABS cut relay.
relay is made in accordance with Tech 2’s instruction. The circuit is normal if the working sound of the
exhaust brake cut relay is made in accordance with
Tech 2’s instruction.
Actuator Test
Actuator 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
Hold Valve Test Select a Iso Solenoid

Purpose: The purpose of this test is to detect brake from the Front Left Solenoid Valve Test
pipe and valve line harness wire wrong connections Function Menus.
and valve trouble.
This test will help you confirm the result of your repair
service including the removal/reinstallation of brake Front Left Solenoid Valve Test
pipe, valve line harness and valve.
Actuator Test
Dump Solenoid
F0: ABS 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
F5: Rear Right Solenoid Valve Test observe the lifting up points. Refer to
F6: ABS Check Light Test vehicle lifting points in 0A section.
Release Valve Test Select a Dump Solenoid

Purpose: The purpose of this test is to detect brake from the Front Left Solenoid Valve Test
pipe and valve line harness wire wrong connections Function Menus.
and valve trouble.
This test will help you confirm the result of your repair
service including the removal/reinstallation of brake Front Left Solenoid Valve Test
pipe, valve line harness and valve.
Actuator Test
Iso Solenoid
F0: ABS Relay Test

3. Press the Release Valve “ON” Soft Key with the

brake pedal stepped on.
4. Make sure that the Release Valve “ON” aimed at
by Tech 2 and the wheel released position are the
same. If different, check brake pipe, valve line
Test conditions: The ignition key is in the “ON” position
harness wiring and H/UNIT. Repair is needed if
with the four wheels lifted up. The brake pedal is
abnormality is found.
stepped on, released and stepped on again with the
parking brake released. 5. Conduct Step 2 through Step 5 above on all the
four wheels.
Test procedure:
CAUTION: When conducting this test, please
1. Connect Tech 2 with the vehicle, and select observe the following cautions.
Special Function from the menus.
1. Do not start the engine without fail.
2. Select a Release Valve Menu from the Special 2. Lift up the vehicle at the level floor.
Function Menus. • Secure a clearance from the floor surface
enough to allow the lifted tire to rotate.
3. Maintain the lift up.
Actuator Test 4. Wipe the floor surface to remove water and oil
so that the surface may become unslippery.
F0: ABS Relay Test 5. Do not load the vehicle.
F1: Return Pump Relay Test • When lifting up the vehicle, be sure to
F3: Front Right Solenoid Valve Test observe the lifting up points. Refer to
F4: Rear Left Solenoid Valve Test vehicle lifting points in 0A section.
EHCU Connector Pin-out Checks • Perform checks with high impedance digital
• Disconnect EHCU. multimeter 5-8840-0285-0 (J-39200) or equivalent.
Key Nominal Value

Multimeter Measure
No. Circuit to be Tested Switch (24V Battery Note
Scale/Range between Pin
Position Vehicle)
1 EHCU Power Circuit OFF VDC 3(+)-1(-) 0-0.3V
ON VDC 3(+)-1(-) 9.5-16.5V
(16.5-34V)
OFF VDC 2(+)-1(-) 9.5-16.5V
(16.5-34V)
OFF VDC 24(+)-1(-) 9.5-16.5V
(16.5-34V)
2 EHCU Ground Circuit OFF Ω 1(+)-GND Less than 0.01 Ω
OFF Ω 23(+)-GND Less than 0.01 Ω
3 EXHIN Circuit ON VDC 7(+)-1(-) 9.5-16.5V Engine Run
(16.5-34V)
4 EXHOUT Circuit ON VDC 8(+)-1(-) 9.5-16.5V
(16.5-34V)
OFF VDC 8(+)-1(-) 0-0.3V
5 Brake Switch Signal OFF VDC 16(+)-1(-) 0-0.3V
Circuit
OFF VDC 16(+)-1(-) 9.5-16.5V Apply Brake
(16.5-34V) Pedal
6 ABS W/L Circuit ON VDC 6(+)-1(-) 9.5-16.5V
(16.5-34V)
OFF VDC 6(+)-1(-) 0-0.3V
7 FL Speed Sensor OFF kΩ 10(+)-11(-) 1-2kΩ
OFF kΩ 10(+)-1(-) More than
1000kΩ
OFF VDC 10(+)-11(-) More than 200mV Turn Wheel at
0.5RPS
8 FR Speed Sensor OFF kΩ 32(+)-33(-) 1-2kΩ
OFF kΩ 32(+)-1(-) More than
1000kΩ
OFF VDC 32(+)-33(-) More than 200mV Turn Wheel at
0.5RPS
Circuit Diagram-FOR 12VOLT

F-17
STOP LAMP SW ; STOP LAMP
3W 10A 0.5G/Y 1 2 0.5G
B-66 B-66
FL-4
ABS
60A 3R 3R
RELAY ;
EXH.BRAKE F-14
FL-1 5W EXH.BRAKE
MAIN 5 2B/R 15A
80A B-38 0.5LG
8B 8W 2 5W 3W 1
H-6 B-38
H-5
RELAY; 0.5W/L 2 4 40
B-38 B-38
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
P-5 J-16 J-16 0.5LG/R 2 5 0.3B

B-31 B-31
5 4
0.5LG/B 3 6 0.5BR/R
B-31 B-31
1
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
0.5G 11 0.5G 2 0.5G

H-5 H-16
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
MAG.VALVE ; VSV ; VSV ;

EXH.BRAKE INT.THROTTLE FICD
J-31 J-40 J-41

2 2 2
0.5B
0.5B
0.5B
3B 3B
3B
2B 2B 0.5B
Circuit Diagram-FOR 24VOLT
F-10
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
60A RELAY ;
P-2
TAIL
RELAY ;
0.3B
EXH.B/CUT
SW ;
(ABS)
ENG.WARMING
0.3B
3W/B
J-16 J-16 0.5LG/R 2 5 0.3B

P-3 B-31 B-31
5 4
BATTERY 0.5LG/B 3 6 0.5BR/B
P-4 B-31 B-31
1
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
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
8 JOINT
3B 3B 3B
2B 2B 2B
0.5G 11 0.5G 2 0.5G

H-5 H-16
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
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
3B 23 FL SIG J-500 J-75

(FRT,LH)
33 0.5R/B 2
3B 1 FL GRD J-500 J-75
J-500 VALVE GND
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
0.5B/Y(NQR) 17 4 0.3W/G 34 0.3W/G

RELAY ; J-500 MODE3 FRASH J-500 H-5
ENG.WARMING CUT
J-15 J-15 ALDL
C/U ; ENGINE B-79
CONNECTOR
1 2
0.5BR/R
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
VSV ; MAG.VALVE ; VSV ;

FICD EXH.BRAKE INT.THROTTLE
EX-1 J-31 EX-3

2 2 2
12
0.5B
0.5B
H-13
0.5B
0.5B
3B 3B
3B
0.5B
Circuit Diagram-12VOLT FOR 2003 YEAR MODEL
F-17
3W 10A 0.5G/Y 1 4 0.5G
B-66 B-66
FL-4
ABS
60A 3R 3R
RELAY ;
B-343 EXH.BRAKE F-14
FL-1 JOINT EXH.BRAKE
CONNECTOR 15A
MAIN 5 2B/R 40 0.5LG
80A 9 B-38 H-5
8B 8W 2 5W 3W 3 8 3W 1
H-6 B-38
RELAY; 0.5W/L 2 4
B-38 B-38
CHARGE
FL-2
P-1
KEY SW
BATTERY
0.3B
50A
P-2
3W/B
P-5
1
H-7 KEY SW
OFF
ACC
3W/B 2 B
B-67 F-12
ON 3 3B/Y
B-67 GAUGE
ST BACK
10A
METER
0.5B/Y
ABS
0.5B/Y 8 7
B-51 B-51
22
H-5
0.5B/Y
0.3W/V
0.5W
3 4
B-35 B-35
RELAY ;
ABS IND.
B-35 B-35
0.5B/Y 5 2
0.3B
0.5B
2B
8 JOINT
3B 2 7 B-29 CONNECTOR 3B
3B
0.5G 11 0.5G 2 0.5G

H-5 H-16
0.5G
0.5G
3R
STOP STOP
0.5LG LAMP LAMP
(LH) (RH)
0.5G EHCU ; ABS
16
RL 12V J-177 J-78
SPEED SENSOR
3R 24 (RR,LH)
J-177 MOTOR +B 34 0.5Y 1
RL SIG J-177 J-78
3R 2
J-177 VALVE +B
32 0.5V 1
3B 23 FL SIG J-177 J-75
(FRT,LH)
33 0.5R/B 2
3B 1 FL GRD J-177 J-75
J-177 VALVE GND
8
J-177 EXH.B/CUT
OUT 10 0.5P 1
FR SIG J-177 J-74
ECM 0.5LG/B 36 0.5LG/B 7 SPEED SENSOR
H-5 J-177 EXH.B/CUT
B-234 (43) (FRT,RH)
IN 11 0.5L 2
FR GRD J-177 J-74
0.3W/V 35 0.3W/V 6
H-5 J-177 IND.
0.5B/Y 3 21 0.5R 4
J-177 IG RR 12V J-177 J-78
SPEED SENSOR
12 0.5W (RR,RH)
3
MODE1 RR SIG J-177 J-78
29 0.3W/B 26
MODE2 J1850 J-177 H-5
4 0.3W/G 27 0.3W/G
MODE3 FRASH J-177 H-5
3B
DATE LINK
B-79
CONNECTOR
16 15 14 13 12 11 10 9
8 7 6 5 4 3 2 1
0.5B
0.5B
0.3W/B
3B 3B
3B
Circuit Diagram-12VOLT FOR 2003 YEAR MODEL
F-10
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
60A RELAY ;
P-2
TAIL
RELAY ;
0.3B
EXH.B/CUT
SW ;
(ABS)
ENG.WARMING
0.3B
3W/B
J-16 J-16 0.5LG/R 2 5 0.3B

P-3 B-31 B-31
5 4
BATTERY 0.5LG/B 3 6 0.5BR/B
P-4 B-31 B-31
1
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 BACK 0.5LG/B
10A
ABS
0.5B/Y
0.5B/Y 8 7
B-51 B-51
22 10
H-5 H-8 METER
0.5B/Y
0.5B/Y
0.3W/V
0.5W
0.5B/Y
H-14 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
5 2
0.3B
E-11
IND.LAMP ; 0.5B
B-69
1 EXH.BRAKE
0.5B
2
0.5LG/R 0.5LG/R 1 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
3
0.5B
17 B-17
H-8 DIODE
SW ; CLUTCH
0.5LG/B 1 2 0.5LG/R 1 2
B-89 B-89 B-17 B-17
0.3B 0.5B
2B
0.5B
0.85B
8 JOINT
3B 3B 3B
2B 2B 2B
0.5G 11 0.5G 2 0.5G

H-5 H-16
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
RL 12V J-177 J-149
SPEED SENSOR
24 (RR,LH)
J-177 MOTOR +B 34 0.5Y 2
H-68 RL SIG J-177 J-149
2 3R 2
J-177 VALVE +B
32 0.5V 1
0.5BR/B
3B 23 FL SIG J-177 J-75

(FRT,LH)
33 0.5R/B 2
3B 1 FL GRD J-177 J-75
11 J-177 VALVE GND
H-8
8
J-177 EXH.B/CUT
OUT 10 0.5P 1
FR SIG J-177 J-74
7 SPEED SENSOR
J-177 EXH.B/CUT
(FRT,RH)
0.5BR/B
IN 11 0.5L 2
FR GRD J-177 J-74
3B
0.3W/V 6 0.3W/V 6
H-5 J-177 IND.
0.5B/Y 3 21 0.5R 2
J-177 IG RR 12V J-177 J-148
0.5BR/B SPEED SENSOR
0.5B/Y(NQR) 12 0.5W (RR,RH)
5 4 15 1
J-177 MODE1 RR SIG J-177 J-148
J-15 J-15
0.5B/Y(NQR) 14 29 0.3W/B 24
RELAY ; J-177 MODE2 J1850 J-177 H-5
ENG.
WARMING 0.5B/Y(NQR) 17 4 0.3W/G 30 0.3W/G
J-177 MODE3 FRASH J-177 H-5
CUT NQR
J-15 J-15 DATA LINK
C/U ; ENGINE B-79
CONNECTOR
1 2
0.5BR/R
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 2 1 0.5LG 0.5LG 14 14 0.3Y
B-75 B-75 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 NKR / NPR FRONT DISC BRAKE
1 3 0.5L/W 37 3
J-23 J-23 H-5 32 J-177 IG
J-23 H-5
2 MODE1
0.5L/G
0.5LG
2 6 MODE2
H-13 H-13
0.5LG
0.5L/G
MODE3
4 1 1
J-41 J-40 J-31 NKR / NPR FRONT DRUM BRAKE
3
J-177 IG
VSV ;
FICD
MODE1
J-41 J-40 VSV ; INT. J-31 MAG.VALVE ;
2 2 THROTTLE 2 EXH.BRAKE
MODE2
0.5B
0.5B
0.5B
12 0.5B/Y 17
J-177 MODE3
H-13
3B 3B
3B
0.5B
Connector List
Connector List
Connector List
Part Location
FUSE BOX ASM STARTER SW J-148 R/RH

F-12,F-14,F-17 (12V) SENSOR (24V)
F-10,F-12,F-14 (24V) B-35,B-38 RELAY BOX RELAY BOX ASM
J-15 (24V),J-16,J-18 RELAY J-149 R/LH
B-17,B-18,J-23 DIODE SENSOR (24V)
FL-1,FL-2,FL-4 FUSIBLE LINK J-78 R/RH,R/LH
B-233,B-234 ECU (24V) SENSOR (12V)
B-29 JOINT CONNECTOR (24V)

(12V)
H-5~H-8 H-16
J-500 (J-177) ABS EHCU

J-74 F/RH SENSOR
BATTERY
B-66 STOPLIGHT SW J-9 EARTH ; FRAME

(BRAKE SW)
B-79 DATA LINK CONNECTOR
B-1 EARTH ; FRAME (FR)
B-7 EARTH ; HEADLIGHT B/T J-75 F/LH SENSOR
B-67 IGNITION SW "A" B-51 ABS WARNING LIGHT (METER)
Symptom Diagnosis 5. Braking sound (from Hydraulic Unit) is heard while

The symptoms that cannot be indicated by the warning not braking.
light can be divided in the following five categories: These are all attributable to problems which cannot be
1. ABS works frequently but vehicle does not detected by EHCU self-diagnosis. Use the customer
decelerate. complaint and a test to determine which symptom is
present. Then follow the appropriate flow chart listed
2. Uneven braking occurs while ABS works.
below.
3. The wheels lock during braking.
4. Brake pedal feel is abnormal
Diagnostic Flow Charts

No. Symptom
Without TECH 2 With TECH 2
1 ABS works frequently but vehicle does not decelerate. Chart A-1 Chart TA-1
2 Uneven braking occurs while ABS works. Chart A-2 Chart TA-2
3 The wheels are locked. Chart A-3 Chart TA-3
4 Brake pedal feel is abnormal. Chart A-4 -
5 Braking sound (from Hydraulic Unit) is heard while not Chart A-5 Chart TA-5
braking.
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
Chart A-2 Uneven Braking Occurs While ABS Works

Step Action Yes No
1 Is there play in each sensor? Go to Step 2 Repair.
Go to Step 5
2 Damage or powdered iron sticking to each sensor/sensor Go to Step 3 Repair.
rotor? Go to Step 5
3 Is the output of each sensor normal? (Refer to chart C-1 or Go to Step 4 Replace sensor or
TC-1) repair harness.
Go to Step 5
4 Is brake pipe connecting order correct? Replace EHCU. Reconnect brake
Go to Step 5 pipe correctly.
Go to Step 5
Chart A-3, TA-3 The Wheels Are Locked

Step Action Yes No
1 Is ABS working? Go to Step 2 Go to Step 4
2 Is vehicle speed under 10 km/h (6mph)? Go to Step 3 Normal.
3 Is sensor output normal? (Chart C-1 or TC-1) Go to Step 4 Replace sensor or
repair harness.
Go to Step 5
4 Is hydraulic unit grounded properly? Replace hydraulic Correct.
unit. Go to Step 5
Go to Step 5
Chart A-4 Brake Pedal Feed Is Abnormal

Step Action Yes No
1 Is the stop light actuated when the brake pedal is depressed? Go to Step 2 Go to Step 3
2 1. Turn the key off. Go to Step 4 Harness NG
2. Disconnect EHCU connector. between brake SW
3. Measure the voltage between J-500 EHCU connector and EHCU.
terminals 16 and 1, when brake pedal is depressed. Go to Step 7
Is the voltage between 9 - 16 V?
3 Is stop light fuse 12V: F-17, 24V: F-10 normal? Go to Step 5 Replace fuse
12V: F-17,
24V: F-10.
Go to Step 7
4 Is there continuity between J-500 EHCU connector terminal 1 Go to Step 6 Repair body
to body ground? grounded harness.
Go to Step 7
5 Is the brake SW normal? Repair stop light Replace brake
harness. SW.
Go to Step 7 Go to Step 7
6 Is the check harness/connector for suspended Hydraulic system Repair harness.
disconnection? leakage or air entry Go to Step 7
Go to Step 7
properly mounted. and diagnostic flow
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
Symptom Diagnosis 4. Brake pedal feel is abnormal

5. ABS operating sound (from Hydraulic Unit) is
(For 2003 Year Model) heard while not braking.
The symptoms that cannot be indicated by the warning
These are all attributable to problems which cannot be
light can be divided in the following five categories:
detected by EHCU self-diagnosis. Use the customer
1. ABS works frequently but vehicle does not complaint and a test to determine which symptom is
decelerate. present. Then follow the appropriate flow chart listed
2. Uneven braking occurs while ABS works. below.
3. The wheels lock during braking.
Diagnostic Flow Charts

No. Symptom
Without TECH 2 With TECH 2
1 ABS works frequently but vehicle does not decelerate. Chart A-1 Chart TA-1
2 Uneven braking occurs while ABS works. Chart A-2 Chart TA-2
3 The wheels are locked. Chart A-3 Chart TA-3
4 ABS operating sound (from Hydraulic Unit) is heard while not Chart A-4 Chart TA-4
braking.
Chart A-1 ABS Works Frequently But Vehicle Does Not Decelerate
Step Action Yes No
1 Inspect the tires. Go to step 2 Repair tires.
Are tire sizes as specified? Go to step 2
Isn’t there any abnormal wear?
2 Is braking force distribution normal between the front and Go to Step 3 Repair brake parts.
rear of the vehicle? Go to Step 7
3 Are axle parts installed normally? Go to Step 4 Repair axle parts.
Go to Step 7
4 Is there play in each wheel speed sensor? Go to Step 5 Repair wheel
speed sensor.
Go to Step 7
5 Is there damage, or powdered iron sticking to each wheel Go to Step 6 Replace sensor or
speed sensor/sensor rotor? sensor rotor.
Go to Step 7
6 Is the output of each wheel speed sensor normal? (Refer to Replace EHCU. Replace wheel
chart C-1 or TC-1) Go to Step 7 speed sensor or
repair harness.
Go to Step 7
7 Reconnect all components and ensure all components are Repeat the “Basic Go to Step 7
Chart TA-1 ABS Works Frequently But Vehicle Does Not Decelerate (Use TECH 2)
Step Action Yes No
1 Return to Chart A-1. Go to step 2 Repair tires.
Was the Chart A-1 from Step 1 to Step 4 finished ? Go to step 1
2 1. Connect TECH 2. Go to Step 3 Replace wheel
2. Confirm the output from each wheelsensor on DATA speed sensor.
DISPLAY. Go to Step 4
Is the minimum vehicle speed output from each sensor
stable at 4 km/h or less?
3 Return to Chart A-1. Go to Step 4 Go to Step 3
Was the Chart A-1 finished?
Chart A-2 Uneven Braking Occurs While ABS Works

Step Action Yes No
1 Is there play in each sensor? Go to Step 2 Repair.
Go to Step 5
2 Damage or powdered iron sticking to each sensor/sensor Go to Step 3 Repair.
rotor? Go to Step 5
3 Is the output of each sensor normal? (Refer to chart C-1 or Go to Step 4 Replace sensor or
TC-1) repair harness.
Go to Step 5
4 Is brake pipe connecting order correct? Replace EHCU. Reconnect brake
Go to Step 5 pipe correctly.
Go to Step 5
Chart TA-2 Uneven Braking Occurs While ABS Works (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 Check the brake pipe connecting. Replace EHCU. Repair brake pipe.
Is brake pipe connecting order correct? Go to Step 4 Go to Step 4
3 Check the wheel speed sensor and repair if necessary (Refer Go to step 4 Go to step 3
to chart C-1 or TC-1).
Is each chart complete?
4 Reconnect all components, ensure all components are Repeat the “Basic Go to step 4
Chart A-3, TA-3 The Wheels Are Locked

Step Action Yes No
1 Is ABS working? Go to Step 2 Go to Step 4
2 Is vehicle speed under 10 km/h (6mph)? Go to Step 3 Normal.
3 Is sensor output normal? (Chart C-1 or TC-1) Go to Step 4 Replace sensor or
repair harness.
Go to Step 5
4 Is hydraulic unit grounded properly? Replace hydraulic Correct.
unit. Go to Step 5
Go to Step 5
Chart A-4, TA-4 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

Choose and trace an appropriate flowchart by the
numbers listed below to find fault and repair.
Code
Item (except
Flash Serial Diagnosis Chart No.
Wiring)
out Communications
12 - Normal - -
13 C0213 Vehicle Type Error EHCU 1
14 C0214 Low Power Voltage of Rear Sensor or
EHCU 2
EHCU 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
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.

(For 2003 Year Model)
Choose and trace an appropriate flowchart by the
numbers listed below to find fault and repair.
Code
Item (except
Flash Serial Diagnosis Wiring) Chart No.
out Communications
12 - Normal - -
13 C0213 Vehicle Type Error EHCU 1
14 C0214 EHCU Abnormality EHCU 2
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
EHCU 8
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
* Important: DTC 20 (Reference Voltage High) cannot be indicated by Tech 2. DTC 20 can be indicated and
confirmed by flashing using Diagnosis Switch.
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
No. Condition “ABS” Warning Light Illumination Pattern Diagnostic

1 Warning light is Normal
actuated normally
2 Warning light is not lit Warning light lighting circuit

trouble→Go to Chart B-1
3 Warning light is Diagnostic trouble codes

actuated while driving are stored.
Display diagnostic trouble
codes and diagnose on a
code basis according to the
flow charts.
Diagnostic Trouble Codes (DTCs)

When the warning light in the meter remains ON, the
EHCU stores the fault identification and disables the
ABS.
1. How to start DTC display:
• Confirm that the vehicle has come to a
complete stop (with the wheels standing still)
and that the brake pedal is not depressed.
(Unless these two conditions are satisfied, DTC
display cannot be started.)
• With the key switch OFF and short B-79
diagnosis connector terminal 12 to ground.
Then turn the key switch ON.
• DTCs can be displayed also by TECH 2.
The DLC (for Tech 2) is located behind the driver side lower cluster panel
2. DTC display: 3. How to erase code:

• DTC is displayed by blinking warning light. • Conduct brake switch ON/OFF operation 6 or
• Double-digit display. more times within 3 seconds of self-diagnosis
• First, normal DTC 12 is displayed three times startup.
and then any other DTCs are displayed three • The code cannot be erased if more than 3
times. (If no other DTCs have been stored, the seconds have passed since self-diagnosis
display of DTC 12 will be repeated.) startup, or if self-diagnosis has started with
brake switched on (brake pedal depressed).
• DTCs can be erased also by Tech 2.
4. An example of DTC display

Display of DTC 23
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.)
5. How to display vehicle model: Vehicle model Illuminating number of times

1) Turn the key switch OFF. NKR, NPR
1
2) Short the diagnosis connector terminal 12 to FRONT DISC BRAKE
ground. NQR 8
3) Slightly push the brake pedal. NKR, NPR
4) Turn the key switch ON. FRONT DRUM BRAKE 5
5) ABS warning light illuminates.
6) Illuminating number of times indicates the
vehicle model.
NKR,NPR
FRONT DRUM BRAKE
0.4 sec. 0.4 sec. 1.2 sec.
NKR,NPR
FRONT DISC BRAKE
Chart B-1-1 With the key in the ON position (Before starting the engine). Warning light
(W/L) is not activated.
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.”
Chart 1 (DTC13/C0213) Vehicle Type Error

1 1. Disconnect EHCU connector. NQR: Go to Step 2 Go to Step 5
2. Turn the key on. All terminal
3. Measure the voltage at terminal 14, 15, battery voltage
and 17. NKR, NPR:
All terminal 0V
2 1. Turn the key off and connect EHCU. - Go to Step 3 Replace the
2. Connect the TECH 2. EHCU.
3. Clear the vehicle type. Go to Step 3
4. Does the warning light turn off?
3 Confirm the vehicle type. - Go to Step 4 Replace the
Is the vehicle type okay? EHCU.
Repeat Step 3
4 Clear the DTC. - Troubleshooting -
completed.
5 Repair harness. - Go to Step 3 Replace the
Does the warning light turn off? EHCU.
Go to Step 3
Chart 2 (DTC14/C0214) Low Power Voltage of Rear Sensor or EHCU Abnormality

1 Perform chart 11 and 12. - Go to Step 2 Go to Step 1
2 1. Turn the key off. - Go to Step 3 Go to Step 4
2. Disconnect the EHCU connector.
3. Measure continuity between the body
ground and J-500 connector terminal 1, 23.
3 1. Connect the EHCU connector. - Go to Step 5 Go to Step 6
2. Clear DTC.
3. Turn the key from off to on and perform
diagnosis procedure.
Does the DTC repeat?
4 Repair the open/short circuit or malfunction at - Go to Step 6 -
connection of connector.
Is this step completed?
5 Replace the EHCU. - Go to Step 6 -
6 1. Install all parts. Verify each part is properly - Go to “Basic Go to Step 6
installed. diagnostic flow
2. Clear DTC. chart”.
Chart 1 (DTC13/C0213) Vehicle Type Error (For 2003 Year Model)

1 1. Disconnect EHCU connector. NQR: Go to Step 2 Go to Step 5
2. Turn the key on. All terminal
3. Measure the voltage at terminal 14, 15, battery voltage
and 17. NKR, NPR
FRONT DISC
BRAKE:
All terminal 0V
NKR, NPR
FRONT DRUM
BRAKE:
Terminal 14, 15:
0V
Terminal 17:
battery voltage
2 1. Turn the key off and connect EHCU. - Go to Step 3 Replace the
2. Connect the TECH 2. EHCU.
3. Clear the vehicle type. Go to Step 3
4. Does the warning light turn off?
3 Confirm the vehicle type. - Go to Step 4 Replace the
Is the vehicle type okay? EHCU.
Repeat Step 3
4 Clear the DTC. - Troubleshooting -
completed.
5 Repair harness. - Go to Step 3 Replace the
Does the warning light turn off? EHCU.
Go to Step 3
Chart 2 (DTC14/C0214) EHCU Abnormality (For 2003 Year Model)

2. Disconnect the EHCU connector.
3. Measure continuity between the body
ground and J-177 connector terminal 1, 23.
2 1. Connect the EHCU connector. - Go to Step 4 Go to Step 5
2. Clear DTC.
3. Turn the key from off to on and perform
diagnosis procedure.
3 Repair the open/short circuit or malfunction at - Go to Step 5 -
connection of connector.
installed. diagnostic flow
Chart 3 (DTC15/C0215) EHCU Voltage OUT of Range

1 Is the battery voltage okay? - Go to Step 2 Go to Step 5
2 1. Turn the key off. 12 V vehicle: Go to Step 3 Go to Step 6
2. Disconnect the EHCU connector. 10-16 V
3. Start the engine. 24 V vehicle:
4. Measure voltage between J-500 connector 17-33.5 V
terminal 2 and J-500 connector terminal 1,
23.
Is the voltage within the specified value?
3 Locate the malfunction of connection in the - Go to Step 4 Go to Step 8
circuit.
Is the circuit malfunction specified?
4 Repair the malfunction and perform diagnosis - Go to Step 7 Go to Step 8
procedure.
5 Charge or replace the battery. - Go to Step 8 -
6 Repair open/short circuit or malfunction at - Go to Step 8 -
connection of connector between J-500
connector terminal 2 and fusible link FL-4.
installed. diagnostec flow
Chart 3 (DTC15/C0215) EHCU Voltage OUT of Range (For 2003 Year Model)
1 Is the battery voltage okay? - Go to Step 2 Go to Step 5
2 1. Turn the key off. 12 V vehicle: Go to Step 3 Go to Step 6
2. Disconnect the EHCU connector. 10-16 V
3. Start the engine. 24 V vehicle:
4. Measure voltage between J-177 connector 17-33.5 V
terminal 2 and J-177 connector terminal 1,
23.
5. Measure voltage between J-177 connector
terminal 24 and J-177 connector terminal
1, 23.
3 Locate the malfunction of connection in the - Go to Step 4 Go to Step 8
circuit.
Is the circuit malfunction specified?
4 Repair the malfunction and perform diagnosis - Go to Step 7 Go to Step 8
procedure.
5 Charge or replace the battery. - Go to Step 8 -
6 Repair open/short circuit or malfunction at - Go to Step 8 -
connection of connector between J-177
connector terminal 2 or 24 and fusible link FL-
4.
installed. diagnostec flow
Chart 4 (DTC25/C0225) Exhaust Brake Cut Circuit Abnormality

1 1. Disconnect EHCU connector. 12 V vehicle: Go to Step 2 Go to Step 4
2. Start the engine. More than 5 V
3. Measure voltage between EHCU terminals 24 V vehicle:
8 and 1. More than 10 V
2 Measure voltage between EHCU terminals 7 12 V vehicle: Go to Step 3 Go to Step 6
and 1. More than 5 V
Is the voltage within the specified value? 24 V vehicle:
More than 10 V
3 Short EHCU terminal 8 to 1. - Replace the Replace the
Is the voltage at EHCU terminal 7 less than 1.5 EHCU. exhaust brake
V? cut relay.
4 Measure resistance of the exhaust brake cut 12 V vehicle: Go to Step 5 Replace the
relay coil. 60-120 ohms exhaust brake
24 V vehicle: cut relay.
210-310 ohms
5 Measure voltage at coil power side of relay box 12 V vehicle: Check harness Repair harness
connector. (key at on position) 10-16 V between EHCU and/or power
Is the voltage within the specified value? 24 V vehicle: terminal 8 and line.
20-32 V exhaust brake
cut relay.
Repair as
necessary.
6 Turn the exhaust brake switch on. - Repair harness Go to exhaust
Does the exhaust brake indicator light turn on? of EHCU brake diagnosis
terminal 7. procedure.
Chart 5 (DTC33/C0233) Motor Drive Circuit Abnormality

2. Measure voltage between EHCU terminals 10-16 V
24 and 1. 24 V vehicle:
Is the voltage within the specified value? 20-32 V
2 Measure continuity between EHCU terminals - Replace the Repair the
23 and 1. EHCU. harness.
3 Check the ABS fusible link (12V: 60A, 24V: - Repair the Replace the
40A). harness. ABS fusible link
Is it okay? (12V: 60A,
24V: 40A).
Chart 6 (DTC 34/C0234) Abnormal Motor Rotation

• Replace EHCU.
Chart 4 (DTC25/C0225) Exhaust Brake Cut Circuit Abnormality (For 2003 Year Model)
2. Start the engine. More than 5 V
3. Measure voltage between EHCU terminals 24 V vehicle:
8 and 1. More than 10 V
2 Measure voltage between EHCU terminals 7 12 V vehicle: Go to Step 3 Go to Step 6
and 1. More than 5 V
Is the voltage within the specified value? 24 V vehicle:
More than 10 V
3 Short EHCU terminal 8 to 1. - Replace the Replace the
Is the voltage between EHCU terminal 7 and 1 EHCU. exhaust brake
less than 1.5 V? cut relay.
4 Measure resistance of the exhaust brake cut 12 V vehicle: Go to Step 5 Replace the
relay coil. 60-120 ohms exhaust brake
24 V vehicle: cut relay.
210-310 ohms
5 Measure voltage at coil power side of relay box 12 V vehicle: Check harness Repair harness
connector. (key at on position) 10-16 V between EHCU and/or power
Is the voltage within the specified value? 24 V vehicle: terminal 8 and line.
20-32 V exhaust brake
cut relay.
Repair as
necessary.
6 Turn the exhaust brake switch on. - Repair harness Go to exhaust
Does the exhaust brake indicator light turn on? of EHCU brake diagnosis
terminal 7. procedure.
Chart 5 (DTC33/C0233) Motor Drive Circuit Abnormality (For 2003 Year Model)
2. Measure voltage between EHCU terminals 10-16 V
2 Measure continuity between EHCU terminals - Replace the Repair the
23 and 1. EHCU. harness.
24V: 40A).
Chart 6 (DTC 34/C0234) Abnormal Motor Rotation

• Replace EHCU.
Chart 7 (DTC41/C0241) Solenoid Valve Power Supply Abnormality

1 1. Disconnect EHCU connector. 12 V vehicle: Replace the Go to Step 2
2. Measure voltage between EHCU terminals 10-16 V EHCU.
24V: 40A).
Chart 8 (DTC 43, 45/C0243, C0245) Solenoid Valve Circuit Abnormality

• Replace EHCU.
Chart 9 (DTC51/C0251) FL Speed Sensor Circuit Abnormality

1 1. Disconnect EHCU connector. 1-2 k ohms Replace the Go to Step 2
2. Measure resistance between EHCU EHCU.
terminals 32 and 33.
Is the resistance within the specified value?
2 1. Disconnect the FL speed sensor - Repair the Replace the FL
connector. harness. speed sensor.
2. Measure the FL speed sensor resistance.
Is the resistance okay?
Chart 10 (DTC52/C0252) FR Speed Sensor Circuit Abnormality

2 1. Disconnect the FR speed sensor - Repair the Replace the FR
2. Measure the FR speed sensor resistance.
Is the resistance okay?
Chart 9 (DTC51/C0251) FL Speed Sensor Circuit Abnormality (For 2003 Year Model)
2 1. Disconnect the FL speed sensor 1-2 k ohms Repair the Replace the FL
2. Measure the FL speed sensor resistance.
Chart 10 (DTC52/C0252) FR Speed Sensor Circuit Abnormality (For 2003 Year Model)
2 1. Disconnect the FR speed sensor 1-2 k ohms Repair the Replace the FR
2. Measure the FR speed sensor resistance.
Chart 11 (DTC53/C0253) RL Speed Sensor Circuit Abnormality

1 1. Disconnect EHCU connector. - Go to Step 2 Repair the
2. Disconnect RL speed sensor connector. harness.
3. Measure continuity between EHCU
terminal 22 and positive side of chassis
harness connector connected to RL speed
sensor.
2 Measure continuity between EHCU terminals - Go to Step 3 Repair the
22 and 1. harness.
3 1. Start the engine. Less than 2 V Go to Step 4 Repair the
2. Measure voltage between EHCU terminals harness.
22 and 1.
4 Measure continuity between EHCU terminal 34 - Go to Step 5 Repair the
and positive side of chassis harness connector harness.
connected to RL speed sensor.
34 and 1. harness.
34 and 1.
7 Check the RL speed sensor (Refer to chart C- 0.2-4.5 V Replace the Replace the RL
1-3 or TC-1). EHCU. speed sensor.
specified value?
Chart 11 (DTC53/C0253) RL Speed Sensor Circuit Abnormality (For 2003 Year Model)
2. Disconnect EHCU connector J-177 and RL
speed sensor connector J-149 (J-78).
3. Check the continuity between connector J-
177 terminal 34 and sensor connector J-
149 (J-78) terminal 2 (1).
2 1. Check the continuity between connector J- - Go to Step 7 Go to Step 3
177 terminal 34 and connector J-177
terminal 1.
149 (J-78) terminal 1 (2).
terminal 1.
5 1. Connect the connector J-177 with EHCU. 9-16V Go to Step 6 Go to Step 7
2. Turn the key on.
connector J-149 (J-78) terminal 1 (2)
(vehicle side) and ground.
specified value?
6 Check the RL sensor output. (Refer to Chart - Go to Step 8 Go to Step 9
C-1-3)
Is the DTC repeated?
7 Repair open circuit, poor connection and/or - Go to Step 9 Go to Step 7
short circuit between the EHCU connectors
and speed sensor connectors.
Is this step complete?
8 Replace EHCU. - Go to Step 9 Go to Step 8
9 1. Reconnect all components, ensure all - Go to “Basic Go to Step 9
Chart 12 (DTC54/C0254) RR Speed Sensor Circuit Abnormality

1 1. Disconnect EHCU connector. - Go to Step 2 Repair the
2. Disconnect RR speed sensor connector. harness.
3. Measure continuity between EHCU
terminal 21 and positive side of chassis
harness connector connected to RR speed
sensor.
21 and 1. harness.
21 and 1.
4 Measure continuity between EHCU terminal 12 - Go to Step 5 Repair the
and positive side of chassis harness connector harness.
connected to RR speed sensor.
12 and 1. harness.
12 and 1.
7 Check the RR speed sensor (Refer to chart c- 0.2-4.5 V Replace the Replace the RR
1-4 or TC-1). EHCU. speed sensor.
specified value?
Chart 12 (DTC54/C0254) RR Speed Sensor Circuit Abnormality (For 2003 Year Model)
2. Disconnect EHCU connector J-177 and RL
speed sensor connector J-148 (J-78).
3. Check the continuity between connector J-
148 (J-78) terminal 1 (3).
terminal 1.
148 (J-78) terminal 2 (4).
terminal 1.
5 1. Connect the connector J-177 with EHCU. 9-16V Go to Step 6 Go to Step 7
2. Turn the key on.
connector J-148 (J-78) terminal 2 (4)
(vehicle side) and ground.
specified value?
6 Check the RL sensor output. (Refer to Chart - Go to Step 8 Go to Step 9
C-1-4)
Is the DTC repeated?
7 Repair open circuit, poor connection and/or - Go to Step 9 Go to Step 7
short circuit between the EHCU connectors
and speed sensor connectors.
8 Replace EHCU. - Go to Step 9 Go to Step 8
Chart 13 (DTC 61/C0261) Abnormal FL Speed Sensor Signal

1 Have the vehicle been jacked up? - Be careful that Repair tires.
Have two or three wheels been turned on the the system may Go to step 2
brake tester intentionally? fail if two or
three wheels are
turned forcibly.
The flow is now
complete.
2 Are tire pressures, sizes and wear normal? - Go to step 3 Repair tires.
Go to step 2
3 Is there play in the FL wheel bearing? - Go to Step 12 Go to Step 4
4 Is there play in the FL speed sensor/sensor - Go to Step 13 Go to Step 5
rotor?
5 Is there powdered iron sticking to FL speed - Go to Step 14 Go to Step 6
sensor/sensor rotor?
6 Check the FL speed sensor. (Refer to Chart C- - Go to Step 7 Go to Step 10
1-1 or TC-1)
Is the FL sensor output normal?
7 Is there a broken tooth or indentation in the - Go to Step 15 Go to Step 8
sensor rotor?
8 Using DVM, measure the resistance between 1000 k ohms or Go to Step 9 Go to Step 11
J-177 EHCU connector terminal 33 and more
ground.
Does the DVM display a resistance within the
specified value?
9 1. Clear diagnostic trouble code. - Go to Step 20 Go to Step 18
2. Test drive and perform system self-check.
10 Is there damage or indentation in the speed - Go to Step 16 Go to Step 17
sensor?
11 1. Disconnect FL sensor connector. 1000 k ohms or Go to Step 19 Go to Step 16
2. Using DVM, measure the resistance more
between J-75 sensor connector terminal 2
and ground.
specified value?
12 Adjust wheel bearing preload. - Go to Step 21 -
Is action complete?
13 Repair or replace speed sensor/sensor rotor. - Go to Step 21 -
Is action complete?
14 Repair speed sensor/sensor rotor. - Go to Step 21 -
Is action complete?
15 Replace sensor rotor. - Go to Step 21 -
Is action complete?
16 Replace FL speed sensor. - Go to Step 21 -
Is action complete?
17 Check the FL speed sensor circuit. Refer to - Verify repair
Chart 9.
Is action complete?

18 Check for a poor connection and an open - Go to Step 21 -
circuit on the harness between EHCU and
sensor connectors.
Refer to “Note on Intermittents” described in
earlier this section.
Is action complete?
19 1. Locate open circuit, poor connection or - Go to Step 21 Go to Step 21
short circuit on the harness between EHCU
and sensor connectors.
2. Repair the harness.
Is action complete?
20 Replace EHCU. - Go to Step 21 -
Is action complete?
* Before 2002 year model vehicle except Step 1 and Step 2.
Chart 14 (DTC 62/C0262) Abnormal FR Speed Sensor Signal

three wheels are
turned forcibly.
The flow is now
complete.
Go to step 2
3 Is there play in the FR wheel bearing? - Go to Step 12 Go to Step 4
4 Is there play in the FR speed sensor/sensor - Go to Step 13 Go to Step 5
rotor?
5 Is there powdered iron sticking to FR speed - Go to Step 14 Go to Step 6
6 Check the FR speed sensor. (Refer to Chart - Go to Step 7 Go to Step 10
C-1-2 or TC-1)
Is the FR sensor output normal?
sensor rotor?
8 Using DVM, measure the resistance between 1000 k ohms or Go to Step 9 Go to Step 11
J-177 EHCU connector terminal 11 and more
ground.
specified value?
sensor?
11 1. Disconnect FR sensor connector. 1000 k ohms or Go to Step 19 Go to Step 16
2. Using DVM, measure the resistance more
between J-74 sensor connector terminal 2
and ground.
specified value?
Is action complete?
Is action complete?
Is action complete?
Is action complete?
16 Replace FR speed sensor. - Go to Step 21 -
Is action complete?
17 Check the FR speed sensor circuit. Refer to - Verify repair -
Chart 10.
Is action complete?

sensor connectors.
Is action complete?
19 1. Locate open circuit, poor connection or - Go to Step 21 Go to Step 21
Is action complete?
Is action complete?
Chart 15 (DTC 63/C0263) Abnormal RL Speed Sensor Signal

three wheels are
turned forcibly.
The flow is now
complete.
Go to step 2
3 Is there play in the RL wheel bearing? - Go to Step 10 Go to Step 4
4 Is there play in the RL speed sensor/sensor - Go to Step 11 Go to Step 5
rotor?
5 Is there powdered iron sticking to RL speed - Go to Step 12 Go to Step 6
6 Check the RL speed sensor. (Refer to Chart C- - Go to Step 7 Go to Step 9
1-3 or TC-1)
Is the RL sensor output normal?
sensor rotor?
sensor?
Is action complete?
Is action complete?
Is action complete?
Is action complete?
14 Replace RL speed sensor. - Go to Step 18 -
Is action complete?
15 Check the RL speed sensor circuit. Refer to - Verify repair -
Chart 11.
Is action complete?
sensor connectors.
Is action complete?
Is action complete?
Chart 16 (DTC 64/C0264) Abnormal RR Speed Sensor Signal

three wheels are
turned forcibly.
The flow is now
complete.
Go to step 2
3 Is there play in the RR wheel bearing? - Go to Step 10 Go to Step 4
4 Is there play in the RR speed sensor/sensor - Go to Step 11 Go to Step 5
rotor?
5 Is there powdered iron sticking to RR speed - Go to Step 12 Go to Step 6
6 Check the RR speed sensor. (Refer to Chart - Go to Step 7 Go to Step 9
C-1-4 or TC-1)
Is the RR sensor output normal?
sensor rotor?
sensor?
Is action complete?
Is action complete?
Is action complete?
Is action complete?
14 Replace RR speed sensor. - Go to Step 18 -
Is action complete?
15 Check the RR speed sensor circuit. Refer to - Verify repair -
Chart 12.
Is action complete?
sensor connectors.
Is action complete?
Is action complete?
Chart 17 (DTC65/C0265) Tire Size Error (Except 2003 Year Model)

1 Does the tire size match the vehicle - Go to Step 2 Replace the
specification? abnormal tire.
2 Check wear and inflation of the tire. - Go to Step 3 Repair or
Are they okay? replace the
abnormal tire.
3 Are the sensor rotors normal? - Go to Step 4 Replace the
abnormal
sensor rotor.
4 Test run the vehicle. - Replace the Recheck the
Does the malfunction repeat. EHCU. DTC.
Unit Inspection Procedure DIAGNOSIS” and “DIAGNOSIS BY ‘ABS’ WARNING

This section describes the following inspection LIGHT ILLUMINATION PATTERN”:
procedures referred to during “SYMPTOM
without TECH 2 with TECH 2

Speed Sensor Output Inspection Chart C-1-1 to C-1-4 Chart TC-1
Chart C-1-1 FL Speed Sensor Output Inspection Procedure

1 1. Turn the key off. 200 mV or more Go to Step 5 Go to Step 2
2. Disconnect EHCU connector.
3. Jack up the vehicle, with all wheels off the
ground.
4. Measure the AC voltage between J-500 (J-
177) EHCU connector terminals 32 and 33
while turning FL wheel at a speed of 0.5
RPS.
specified value?
2 1. Disconnect FL sensor connector. 1.0-2.0 k ohms Go to Step 4 Go to Step 3
2. Using DVM, measure the resistance
between J-75 sensor connector terminals 1
and 2.
specified value?
3 1. Locate open circuit, poor connection or - Go to Step 5 -
Is action complete?
4 Replace FL sensor. - Go to Step 5 -
Is action complete?
Chart C-1-2 FR Speed Sensor Output Inspection Procedure

1 1. Turn the key off. 200 mV or more Go to Step 5 Go to Step 2
ground.
4. Measure the AC voltage between J-500 (J-
177) EHCU connector terminals 10 and 11
while turning FR wheel at a speed of 0.5
RPS.
specified value?
2 1. Disconnect FR sensor connector. 1.0-2.0 k ohms Go to Step 4 Go to Step 3
2. Using DVM, measure the resistance
between J-74 sensor connector terminals 1
and 2.
specified value?
3 1. Locate open circuit, poor connection or - Go to Step 5 -
Is action complete?
4 Replace FR sensor. - Go to Step 5 -
Is action complete?
Chart C-1-3 RL Speed Sensor Output Inspection Procedure

1 1. Turn the key off. 0.2-4.5V Go to Step 5 Go to Step 2
ground.
4. Connect a 120 ohms resistor between
J-500 (J-177) EHCU connector terminal 22
and ground. Apply voltage of 12V to EHCU
connector terminal 22.
5. Using DVM, measure the DC voltage
between J-500 (J-177) connector terminal
22 and ground while turning RL wheel at a
speed of 0.5 RPS.
specified value?
2. Disconnect RL sensor connector.
sensor connector terminal 2 (sensor side)
and ground.
4. Apply 12V voltage at sensor connector
terminal 1 (sensor side).
between sensor connector terminal 2
(sensor side) and ground while turning RL
wheel at a speed of 0.5 RPS.
specified value?
3 1. Locate open circuit, poor connection short - Go to Step 5 -
sensor connectors.
Is action complete?
4 Replace RL sensor. - Go to Step 5 -
Is action complete?
Legend
(1) Battery (4) Speed Sensor
(2) DVM
(3) Resistor
Chart C-1-4 RR Speed Sensor Output Inspection Procedure

ground.
J-500 (J-177) EHCU connector terminal 21
and ground.
between J-500 (J-177) connector terminal
21 and ground while turning RR wheel at a
speed of 0.5 RPS.
specified value?
2. Disconnect RR sensor connector.
sensor connector terminal 2 (sensor side)
and ground.
4. Apply 12V voltage at sensor connector
terminal 1 (sensor side).
between sensor connector terminal 2
(sensor side) and ground while turning RR
wheel at a speed of 0.5 RPS.
specified value?
3 1. Locate open circuit, poor connection short - Go to Step 5 -
sensor connectors.
Is action complete?
4 Replace RR sensor. - Go to Step 5 -
Is action complete?
Legend
(1) Battery (4) Speed Sensor
(2) DVM
(3) Resistor
Chart TC-1 Sensor Output Inspection Procedure (Use TECH 2)

Step Action Yes No
1 1. Connect TECH 2. Go to Step 2 Go to Step 6
2. Check the minimum speed of each sensor by WHEEL
SENSORS.
Is the sensor speed more than 5km/h (3mph)?
2 Check the sensor harness for suspected disconnection Replace speed Repair.
(check while shaking harness/connector). sensor. Go to Step 3
Is the sensor harness connection normal? Go to Step 3
3 Check the minimum speed of each sensor by WHEEL Go to Step 4 Go to Step 6
SENSORS.
Is the sensor speed more than 5 km/h (3mph)?
4 Check the sensor rotor. Go to Step 5 Replace sensor
Is the sensor rotor normal? rotor.
Go to Step 5
5 Check the minimum speed of each sensor by WHEEL Repair harness or Go to Step 6
SENSORS. connector between
Is sensor speed more than 5 km/h (3 mph)? EHCU and speed
sensor.
Go to Step 6
Chart TC-1 Sensor Output Inspection Procedure (Use TECH 2) (For 2003 Year Model)
Step Action Yes No
1 1. Connect TECH 2. Go to Step 2 Go to Step 6
2. Check the minimum speed of each sensor by WHEEL
SENSORS.
2 Check the sensor harness for suspected disconnection Replace speed Repair.
(check while shaking harness/connector). sensor. Go to Step 3
Is the sensor harness connection normal? Go to Step 3
3 Check the minimum speed of each sensor by WHEEL Go to Step 4 Go to Step 6
SENSORS.
4 Check the sensor rotor. Go to Step 5 Replace sensor
Is the sensor rotor normal? rotor.
Go to Step 5
5 Check the minimum speed of each sensor by WHEEL Repair harness or Go to Step 6
SENSORS. connector between
Is sensor speed more than 4 km/h (3 mph)? EHCU and speed
sensor.
Go to Step 6
Electronic Hydraulic Control Unit (EHCU)

Removal Installation
1 To install, follow the removal steps in the reverse
order, noting the following points.
NOTE:
• If welding work is to be performed on the vehicle
using an electric arc welder, the EHCU should be
removed from the vehicle before the welding
4 operation begins.
• Do not put a radio equipment etc, that emits strong
radio wave near the EHCU.
• Do not wet the control unit. If wetted, wipe off water
immediately and dry it fully.
5
3 • Never loosen any screw on the control unit.
• Do not paint the control unit.
• Prevent possible electrostatic discharge damage.
• Do not touch the control unit pin type terminal with
2 a metalic tip of a screwdriver or tester.
• Do not apply voltage to the terminal.
Legend
(1) Brake Pipe
(2) EHCU Bracket Fix Bolt & Nut
(3) EHCU Bracket
(4) Harness Connector
(5) EHCU
1. Disconnect battery ground cable.

2. Disconnect brake pipes.
3. Remove EHCU bracket fix bolts & nut.
4. Remove EHCU bracket.
5. Remove EHCU.
Legend
(1) Master Cylinder (front)
(2) Master Cylinder (rear)
(3) Rear Right Wheel Cylinder
(4) Rear Left Wheel Cylinder
(5) Front Right Wheel Cylinder
(6) Front Left Wheel Cylinder
Methods of Matching and Matching

Taking off Connectors Turn the lever to direction A and fix the lever lock to
Before Matching the housing.
Semi Matching Finished Matching

Wire harness side connector should be inserted to On a vehicle in which the harness is clamped onto the
equipment side, then lever folds up about 30°. EHCU bracket, clamp the harness after matching the
connectors.
NOTE:
NOTE:
Check the lever folding up.
Check the lever lock is fixed to housing certainly. The
lever or housing can be broken by turned to direction A
without the lever folding up (30°).
Condition of matching Taking off

On a vehicle in which the harness is clamped onto the Turn the lever to direction B.
EHCU bracket, loosen the before taking off the When you feel the lever heavy in your hand (after
connectors. turning about 40 degrees), turn the lever in the
direction of C.
The lever will not turn and the connector may fail if
force is applied in the direction of D.
Release of lock
Push lever lock down until the condition it can be
released.
NOTE:
The lockarm can be broken by being turned to
direction B in case of incomplete locking.
NOTE:
Check division A can be released.
Check the lever is turned certainly and take connector

off to direction E.
Finished Taking off

Front Speed Sensor

Front Speed Sensor and Associated Parts
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.
Front Speed Sensor Rotor

Front Speed Sensor Rotor and Associated Parts
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.
6. Remove speed sensor rotor.

7. Remove inner bearing, oil seal spacer.
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.
• Hub bearing preload

New Hub Bearing 9.8-24.5N (1-2.5kgf/2.2-5.5lbf)
Reused Hub Bearing 4.9-19.6N (0.5-2kgf/1.1-
4.4lbf)
Rear Speed Sensor

Rear Speed Sensor and Associated Parts
Legend
(1) Brake Drum (3) Speed Sensor
(2) Speed Sensor Fixing Bolt (4) Speed Sensor Bracket
Removal Inspection and Repair

1. Check the speed sensor for presence of foreign
materials; remove any dirt, etc.
2. Check the speed sensor for damage, and replace
the speed sensor if necessary.
3. Check the speed sensor harness for a short or an
open, and replace with a new one if necessary. To
check for harness short or open, bend or stretch
the cable while checking for continuity.
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
(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.
Rear Speed Sensor Rotor

Rear Speed Sensor Rotor and Associated Parts
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
Removal Inspection and Repair

1. Remove brake drum. 1. Check the speed sensor rotor for damage
2. Remove axle shaft. including tooth chipping. If damaged, replace
3. Remove outer oil seal, using a screwdriver. speed sensor rotor.
4. Remove lock washer.
5. Remove bearing nut with a hub bearing nut
Installation
wrench. 1. Using a bench press, install speed sensor rotor.
6. Remove hub assembly from axle case. NOTE: Do not reuse the sensor rotor.
2. Install spacer on to the axle case.
7. Remove outer bearing from hub assembly.
3. Apply grease into the outer and inner bearings and
8. Remove speed sensor rotor from hub assembly.
install bearings in the hub.
9. Remove inner bearing and inner oil seal from axle
4. Install outer oil seal into hub.
case.
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.
11. Install brake drum.
4) Set the spring balancer to the wheel pin in the

position shown in the illustration.
5) Measure the hub bearing preload by carefully
pulling on the spring balancer and noting the
indicator reading.
Hub Bearing Preload (At Wheel Pin)
42-52 N (4.3-5.3kgf/9.4-11.6lbf)
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
(1) PCMCIA Card

(2) RS232 Loop Back
Connector
(3) SAE 16/19 Adapter
(4) DLC Cable
(5) Tech 2
LGBRK-WE-0131
You are requested to order this manual using the

manual number that is shown above.
This manual is applicable for vehicles in all countries

except the USA and Canada.
All rights reserved. This manual may not be

reproduced in whole or in part, without the permission
in writing of ISUZU MOTORS LIMITED.
Issued by
ISUZU MOTORS LIMITED
INTERNATIONAL SERVICE DEPARTMENT
Tokyo, Japan
Second edition July., 2003

LGBRK-WE-0131 PRINTED IN JAPAN

Anti-Lock Brake System (ABS) : Workshop Manual

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Anti-Lock Brake System (ABS) : Workshop Manual

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WORKSHOP MANUAL

NKR . NPR . NQR

ANTI-LOCK BRAKE SYSTEM

Tech 2 Scan Tool ........................................................................................................ 5A4 -10

Chart 1 (DTC 13/C0213) Vehicle Type Error.............................................................. 5A4 -48

Chart TC-1 Sensor Output Inspection Procedure (Use TECH 2)

General Description determine when a wheel is about to stop turning and

System Components ABS Warning Light

Electronic Hydraulic Control Unit (EHCU)

Vehicles equipped with the Anti-lock Brake System

Wheel Speed Sensor

until there is no longer a need for the anti-lock function VDC

General Service Precautions WARNING LIGHT ILLUMINATION PATTERN”. In

Basic Diagnostic Flow Chart

Basic Inspection Procedure

Tech 2 Scan Tool

Tech 2 Features 6. Turn on the vehicle ignition.

Operating Procedure (For Example)

System Selection Menu

Chassis F1: Clear DTC Information

Confirm The following is a brief description of each of the sub

F3: Actuator Test

There are two options available in Tech 2 DTC mode

When CODE “13” is displayed (Vehicle Type Error)

Diagnostic Trouble Codes

F0: Read DTC Info

F1: Clear DTC Info

F2: DTC Info Do you want clear &

YES: Clear vehicle type and reread vehicle harness

Current Diagnostic Trouble Codes

History Diagnostic Trouble Codes

Plotting Snapshot Graph

Flow Chart for Snapshot Replay (Plotting Graph)

Tech 2 Data Display Special Function

F0: ABS Relay Test

ABS Warning Lamp ABS Motor

Actuator Test Actuator Test

F0: ABS Relay Test F0: ABS Relay Test

ABS Relay Exhaust Brake Cut Relay

Hold Valve Test Select a Iso Solenoid

F3: Front Right Solenoid Valve Test

Release Valve Test Select a Dump Solenoid

F3: Front Right Solenoid Valve Test

3. Press the Release Valve “ON” Soft Key with the

Key Nominal Value

Circuit Diagram-FOR 12VOLT

P-5 J-16 J-16 0.5LG/R 2 5 0.3B

0.5G 11 0.5G 2 0.5G

MAG.VALVE ; VSV ; VSV ;

J-31 J-40 J-41

Circuit Diagram-FOR 24VOLT

J-16 J-16 0.5LG/R 2 5 0.3B

0.5G 11 0.5G 2 0.5G

3B 23 FL SIG J-500 J-75

0.5B/Y(NQR) 17 4 0.3W/G 34 0.3W/G

VSV ; MAG.VALVE ; VSV ;

EX-1 J-31 EX-3

Circuit Diagram-12VOLT FOR 2003 YEAR MODEL