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Pinpoint Test Y - Brake Warning Never/Always On

  1. Ensure brake fluid reservoir is full. Turn ignition on. Wait until prove-out cycle is completed. If warning indicator is always on, go to next step. If warning indicator is never on, turn ignition off. Remove instrument cluster. See REMOVAL & INSTALLATION  . Remove indicator bulb. Check for continuity between indicator bulb terminals. If continuity is not present, replace bulb. If continuity is present, go to next step.
  2. Turn ignition off. With instrument cluster removed, disconnect connector C1. Turn ignition on. Measure voltage between pin No. 16 (Yellow/Purple wire) and pin No. 20 (Blue wire) at connector C1. If voltage is 10 volts or less, go to next step. If voltage is greater than 10 volts, replace instrument cluster.
  3. Turn ignition off. Disconnect instrument cluster connector C1. Disconnect brake fluid level switch connector, located under brake fluid reservoir. Remove bulb check relay from main fuse panel. See Fig 1 . Disconnect top Black diode strip from junction box No. 1. Measure resistance of Yellow/Purple wire between connector C1, pin No. 16 and ground. If resistance is greater than 10,000 ohms, go to next step. If resistance is 10,000 or less, repair Yellow/Purple wire circuit.
    Fig 1: Locating Bulb Check Relay (Villager)
    G96C01166
    Fig 2: Identifying Bulb Check Relay Connector Terminals (Villager)
    G96E01167
  4. Leave ignition off. Measure resistance of Yellow/Purple wire between connector C1, pin No. 16 and bulb check relay connector, pin No. 3. See Fig 2 . If resistance is less than 5 ohms, go to next step. If resistance is 5 or more, repair Yellow/Purple wire circuit.
  5. Check RELAYS fuse located in interior fuse panel. If fuse is blown, go to next step. If fuse is okay, go to step 8).
  6. Ensure ignition is off. Replace blown fuse. Turn ignition on. If fuse blows again, again, go to next step. If fuse is okay, go to step 8).
  7. Leave ignition off. Remove RELAYS fuse and bulb check relay. Measure resistance of Blue wire between RELAYS fuse and ground. If resistance is 5 ohms or more, replace RELAYS fuse and go to next step. If resistance is less than 5 ohms, repair Blue wire circuit.
  8. Turn ignition on. Measure voltage between terminal No. 2 (Blue wire) at bulb check relay connector and ground. If voltage is 10 volts or more, go to next step. If voltage is less than 10 volts, repair Blue wire circuit.
  9. Turn ignition off. Ensure top Black diode strip of junction box No. 1 is disconnected. Measure resistance of Blue/Yellow wire between connector C1, pin No. 6 and bulb check relay connector pin No. 1. If resistance is less than 5 ohms, go to next step. If resistance is 5 or more, repair Blue/Yellow wire circuit.
  10. Leave ignition off. Measure resistance of Black wire between bulb check relay connector and ground. If resistance is 5 ohms or less, go to next step. If resistance is greater than 5 ohms, go to step 18).
  11. Leave ignition off and bulb check relay disconnected. Using a jumper wire, connect pin No. 2 of bulb check relay to positive battery terminal. See Fig 2 . Measure resistance between pin No. 3 and No. 5 as follows:
    • With pin No. 2 of bulb check relay connected to positive battery terminal, less than 5 ohms should be present.
    • With pin No. 2 of bulb check relay not connected to positive battery terminal, more than 5 ohms should be present.

    If resistances are as specified, go to next step. If resistances are not as specified, replace bulb check relay.

  12. Leave ignition off and brake fluid level switch disconnected. Remove screen from inside brake master cylinder reservoir. Measure resistance between brake fluid level switch terminals. Using a clean screwdriver, depress brake fluid level switch float. Measure resistance between brake fluid level switch terminals again. If resistance is greater than 10,000 ohms when float is released, and less than 5 ohms when float is depressed, go to next step. If resistances are not as specified, replace brake fluid level switch.
  13. Leave ignition off. Disconnect instrument cluster connector C1. Measure resistance of Yellow/Purple wire between connector C1, pin No. 16 and brake fluid level switch connector. If resistance is 5 ohms or less, go to next step. If resistance is greater than 5 ohms, repair Yellow/Black wire circuit.
  14. Leave ignition off. Measure resistance of Black wire between brake fluid level switch connector and ground. If resistance is 5 ohms or less, go to next step. If resistance is greater than 5 ohms, go to step 18).
  15. Leave ignition off. Disconnect parking brake switch connector (located on pedal). With parking brake released, measure resistance between connector terminal and ground. Set parking brake. Measure resistance between connector terminal and ground again. If resistance with parking brake released is greater than 10,000 ohms and less than 5 ohms when parking brake is set, go to next step. If resistances are not as specified, replace parking brake switch.
  16. Turn ignition off. Ensure top Black diode strip of junction box No. 1 is disconnected. Measure resistance of Yellow/Purple wire between connector C1, pin No. 16 and junction box No. 1 connector pin No. 10. If resistance is less than 5 ohms, go to next step. If resistance is 5ohms or more, repair Yellow/Purple wire circuit.
  17. Leave ignition off. Measure resistance of Green/Black wire between junction box No. 1 connector pin No. 9 and parking brake switch connector terminal. If resistance is 5 ohms or less, replace Black diode strip of junction box No. 1. If resistance is greater than 5 ohms, repair Green/Black wire circuit.
  18. Leave ignition off. Remove joint connector strips from joint connector in main fuse junction panel. Measure resistance of Black wire between pin No. 22 of joint connector and ground. If resistance is 5 ohms or less, go to next step. If resistance is greater than 5 ohms, repair Black wire circuit.
  19. Leave ignition off and joint connector strips removed from joint connector. Measure resistance between pin No. 19 and pin No. 22 of joint connector. Measure resistance between pin No. 21 and pin No. 22 of joint connector. If resistance is 5 ohms or less, repair Black wire circuit. If resistance is greater than 5 ohms, replace joint connector strip.
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