Haima S5. Chassis System. Instruction

Brake system 2F-26

19N.m

3. Use the tool to remove the fastening bolts from

the rear bracket arm ④ ⑤
When mounting bolt tightening torque is: 18 ~
26N.m

Check of handle parking brake

1. Pull the parking brake handle several times.

2. Step the brake pedal several times.

3. Pull the parking brake handle with a force of

245N {25kgf, 55Ibf}, and check the stroke of
parking brake.

Stroke of 9-11 teeth.

Adjustment of parking brake handle stroke

1. Adjust the clearance of brake shoe.

2. Start the engine, and step the brake pedal

several times.

3. Stop

the

engine.

4. Turn the parking handle ① and ③ connect

cable assembly before adjusting nut ②, pull
the handle to test its stroke.

5. After adjusting it, check the following points:

(1) Turn the ignition switch, pull the parking

brake handle by 1 tooth, and confirm that the
parking brake lamp goes on.

(2) Confirm no brake drag of rear brake.

Parameters

General technical parameters

Item Instructions

Stroke of parking brake handle 9 to 11 teeth[tensile force of 245N (25 kgf, 55 Ibf)]

Locking torque parameters

Item Nm

Lb-Ft

Lb-in

Parking handle mounting nut

Parking cable fixed support

mounting bolt

17 -

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Brake system 2F-27

ABS system

Note: when moving or installing other electronic elements, or tools and other equipment are easy to contact
the exposed terminals, disconnect the power cathode lines. It can avoid the personal injury and vehicle
damages to disconnect this wire. The ignition switch must be also in B gear, unless otherwise marked
additionally. Don’t diagnose ABS system, because it will lead to the termination of ABS functions.

Overview

I. Attentions

ABS is a part related to the safety. Therefore, the
following attentions for diagnosis must be also
followed in addition to general safety and
preventive measures during its repair diagnosis.

1. ABS system must be repaired by trained and

skilled technicians, and can be replaced only by
the original part.

2. Before diagnosing ABS system, if the

fundamental brake system has any fault, first
remove it, e.g.:

●

Brake system noises

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Brake system 2F-28

● Overhard

brake

pedal.

● During the common braking operation, The

brake pedal or vehicle vibrates.

●

Runout of vehicle brake.

●

Faults of parking brake system

3. ABS assembly (e.g. ABS electronic control

unit and hydraulic regulator assembly,
excluding the brake pipe, sensor or other
auxiliary devices) can be only replaced as a
whole, and can’t be disassembled for check
or partially replaced/interchanged. Bosch
doesn’t supply any separate spare part, and
doesn’t guarantee the disassembled ABS
assembly, and undertake no responsibility for
bad consequences caused after disassembling
or partially replacing/interchanging ABS
hydraulic regulator.

4. The following two cases indicate that ABS

system detects the faults:

● After turning on the ignition switch, the self-

check of system is finished, and the warning
lamp keeps lightened.

● While the vehicle is driving, the warning lamp

keeps constantly on. At this time, the driver can
apply the regular braking operation, but he
should try his best to reduce the applied
braking force, and prevent the wheel from
locking. After the warning lamp goes on, it’s
required to drive carefully and go to the special
service station immediately for repair, so as to
avoid the occurrence of more accidents,
otherwise it will lead to the traffic accidents.

5. The following points need to be attentioned

while connecting ABS sensor wires:

● Before pulling ABS wire and sensor wire, be

sure to disconnect the ignition switch.

● Ensure the drying and cleanness of connector,

and avoid the entry of any strange substance .

●

The connectors of ABS wires must be installed

in position in horizontal and vertical directions

to avoid their damages.

6. While connecting ABS brake pipes, be sure to

ensure their correct installation. ABS ECU
can’t judge whether the brake pipes are
correctly connected. Any wrong connection
may lead to the serious accident. During the
connection of brake pipe, be sure to follow the
mark on ABS assembly:

● MC1: connect the brake master cylinder brake

pipe 1;

● MC2: connect the brake master cylinder brake

pipe 2;

● FL: connect the brake pipe of left front wheel

brake wheel cylinder;

●

FR: connect the brake pipe of right front wheel
brake wheel cylinder;

● RL: connect the brake pipe of left rear wheel

brake wheel cylinder;

● RR: connect the brake pipe of right rear wheel

brake wheel cylinder.

7. ABS will produce the noises in the following

cases:

● After powering on the vehicle or starting the

engine, it will produce a short sound of “buzz”,
this is a sound of ABS self-check, which is a
normal phenomenon.

● ABS will produce the noises during the

normal

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Brake system 2F-29

operation, which is mainly reflected by the

following aspects:

1) Action sound of motor, solenoid valve and

return pump in ABS hydraulic unit.

2) Sound caused by the bounce of brake pedal.

Impact sound of suspension and body

caused by emergency braking operation.

II. Initial

check

Before the diagnosis of ABS system, first check its
parts, which may cause the faults of ABS system
and be easy to contact, their visual check and
appearance check procedures can determine the
faults quickly, thus their further diagnosis need’s be
diagnosed.

1. Ensure that only the tires and hubs with

recommended sizes are installed on the vehicle.
The patterns and depths of tires on the same
shaft must be the same.

For the details of tire models, please refer to the

operating instructions for vehicle.

2. Check ABS hydraulic regulator, brake pipe and

connection for leakage.

3. Check the fuses of ABS system, ensure that no

fuses are burnt and their models are correct.
ABS system has three fuses separately:

 　Pump motor fuse(40A)

 　Solenoid valve fuse(25A)

 　Electronic control unit fuse (10A)

4. Check the voltage of battery, and check

whether the battery terminals are corroded or
loosened. Normal operating voltage range of
ABS system is 9. 3V-16. 8V.

5. Check whether the bonding point of ABS earth

wire is loosened, and whether its earthed
position is changed.

6. ABS earth wire must have good sealing ability

to prevent the water or moisture from
penetrating into ABS ECU joint through the
hole of wire due to capillary effect (siphon),
thus it can lead to the failure of its function.
Adopted measures: apply the seal gum to
exposed ends of wire, and adopt the shrinkable
tube gland.

7. Apply the visual checks and appearance checks

of the following electric parts:



Whether the wires and connectors of relevant

Apply the seal gum to the exposed end of wire,
and adopt the shrinkable tube gland.

Ignition

coil/ignition

wire/spark plug

Gear ring

Generator

Wheel speed sensor

Water

line

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Brake system 2F-30

ABS system parts are correctly connected,
jammed or slashed.

 The wires shall be arranged near to high-

voltage or high-current device, e.g.high-voltage
power or part, generator, motor, and
stereophonic amplifier attached after sale.
Note: the high-voltage or high-current device
may make the circuit noisy, thus it will disturb
the normal operation of circuit.

 ABS parts are very sensitive for

electromagnetic interference(EMI). In case of
suspecting the intermittent faults, check
whether the thief-proof devices, lamps or
mobile telephones attached after sale are
correctly installed.

8. ABS is an active safety system. Its main

purpose is to adopt the maximum ground
adhering moment, and keep the steer ability of
vehicle and drive stability. However, in case of
exceeding its physical limit or driving on the
wet and slippery road at high speed, ABS can’t
prevent the vehicle from slipping fully, too.

9. In case of too much noise of ABS, it may be

caused by the following cases:

 Loosened fixation of ABS assembly and

ABS support.

 Loosened fixation of ABS support and

vehicle body.



Loss or damages of plastic washers on ABS
support.

Hydroplaning

Don’t cling

Hydroplanin

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Brake system 2F-32

The following meanings of English abbreviations in Fig.:

First circuit of brake master cylinder

Right rear wheel

Second circuit of brake master cylinder

FLEV

left front wheel oil inlet valve

motor

FLAV

left front wheel oil outlet valve

return pump 1

FREV

right front wheel oil inlet valve

return pump 2

FRAV

right front wheel oil outlet valve

Energy accumulator 1

RLEV

Left rear wheel oil inlet valve

Energy accumulator 2

RLAV

Left rear wheel oil outlet valve

left front wheel

RREV

Right rear wheel oil inlet valve

right front wheel

RRAV

Right rear wheel oil outlet valve

Left rear wheel

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Brake system 2F-34

3.2 Definitions of Haima S5 pins

Pin Function

Motor power terminal(positive)

Wheel speed output(right front)

3 EBD

warning

lamp

4 wheel speed sensor signal terminal(right

front)

5 Undefined

Diagnostic K line

7 Undefined

8 wheel speed sensor signal terminal(left

front)

9 Undefined

10 Undefined

11 Undefined

12 Undefined

13 Motor

ground

terminal

14 CAN L (unused)

15 Undefined

16 wheel speed sensor power terminal (right

front)

17 wheel speed sensor power terminal (right

rear)

18 wheel speed sensor signal terminal (left

rear)

19 wheel speed sensor power terminal (left

front)

Function

Undefined

Power end of valve relay

CAN H (unused)

ABS warning lamp

ECU power terminal (ignition power line)

wheel speed sensor signal terminal (right
rear)

brake lamp switch

wheel speed sensor power terminal (left
rear)

Undefined

Speed output

Undefined

ECU ground terminal

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Brake system 2F-35

ABS 9 Fault diagnosis

I. Diagnostic

flow

The vehicle enters into the repair factory.

Analysis of customers’ problems

Reading of fault codes

Faults

Go to Step 4

No faults

Go to Step 6

Record the fault codes, and then remove the fault codes.

Certification and reproduction of faults: accelerate the vehicle speed up to at least 15 km/h,
simulate the reproduction of faults, and read the faults again.

Faults

Current fault code. Go
to Step 9.

No faults

Historical fault code.
Go to Step 9.

For the faults without fault codes, repair and go to Step 9.

Remove the faults as per the list of fault codes, and then go to Step 9.

Remove the faults as per the list of fault symptoms, and then go to Step 9.

Confirm the removal of faults, perform the repair and test on completion.

Avoid the regeneration of faults.

Conclusion

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Brake system 2F-36

II. For the faults without fault codes, repair it.

If the faults occur to the brake system, but ABS has no stored fault codes, and this fault is called as a fault
without fault codes. The fault without fault codes is generally caused by basic faults of brake system. E.g.:

 Leakage of brake fluid (it may cause the softening of brake, overlong stroke of brake pedal, and even

serious failure of brake)

 Application of poor brake fluid(the use of poor brake fluid will corrode the brake pipe and elements

inside ABS hydraulic control module, and lead to the serious failure of brake)

 Existence of air in brake pipe (it may cause the softening of brake and even brake failure)

 Blockage of brake pipe (it may cause the hardening of brake and even brake failure)

 Excessive wears of brake disc (it may cause the softening of brake and even brake failure)

 Faults of booster (it may cause the hardening or softening of brake, overlong stroke of brake pedal and

even still brake failure seriously)

 Wrong connection of brake pipe (it may cause the reduction of ABS performances, whipping and long

braking distance,etc. For the correct installation methods, please refer to the marks near to oil holes in
ABS hydraulic control module: MC1 stands for #1 master cylinder oil pipe; MC2 stands for #2 master
cylinder oil pipe; FL stands for left front wheel cylinder oil pipe; FR stands for right front wheel
cylinder oil pipe; RL stands for left rear wheel cylinder oil pipe; RR stands for right rear wheel
cylinder oil pipe)

Note: no power or power failure of ABS will lead to the constant illumination of ABS warning lamp, but it
has no fault codes.

Suggestions for fault removal: check the corresponding parts as per the fault symptoms, and remove the
faults as per the vehicle maintenance instruction.

III. Repair of occasional faults

In the electronic system, the instant poor contact may appear in the electric circuit and input/output signals,
thus it may cause the occasional faults. Sometimes, the fault causes will disappear automatically, so it’s not
easy to check these problems. In case of meeting the occasional faults, first read the historical fault codes
with a diagnostic unit, check the conditions related to fault codes, simulate the faults as per the following
modes, and check whether the faults are regenerated.

If no fault is regenerated at this time, its diagnosis and repair must be performed after the regeneration of
next fault. Generally speaking, the occasional fault will become a reproducible fault gradually, and it won’t
disappear automatically.

S/N

Possible causes of

faults

Simulated faults

Remarks

When the vibration
may be a major
cause

1. Shake ABS ECU connector lightly
up, down, left or right.
2. Shake ABS wire lightly up, down,
left or right.
3. Shake the sensor lightly up, down,
left or right.
4. Shake other moving parts(e.g.
wheel bearing) lightly.

If the wire is twisted off or broken
due to its excessive tension, it must
be renewed.
The wheel speed sensor wire will
become shortly open-
circuited/short-circuited due to
upward/downward movement of
suspension system during the
movement of vehicle. Therefore,
the actual driving test of vehicle
must be performed while checking
the sensor wires.

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Brake system 2F-37

S/N

Possible causes of

faults

Simulated faults

Remarks

When the
temperature may be
a major cause

1. Heat the parts with possible faults
with an air blower.
2. Check them for cold welding with
cold spraying agent.

When the excessive
electricity load may
be a major cause

1. Turn on all the switches of electric
appliances, including the lamp and
wiper, to make the power supply of
vehicle work at high load.

IV. Analysis of fault codes

4.1 List of fault codes

DTC fault code

Description of fault codes

C190004

High supply voltage of ECU

C190104

Low supply voltage of ECU

C100004

ECU fault(hardware, tiny errors of controller)

C101008

ECU fault(software error)

C006B06

Inappropriate ABS control(overlong control time)

C003108

Faults of left front wheel speed sensor signals: off-limit, loss, noises, intermittent
interruptions

C003200

Fault of left front wheel speed sensor wire: open-circuit

C00A000

Fault of left front wheel speed sensor wire: shorted to ground

C00A100

Fault of left front wheel speed sensor wire: shorted to power supply

C00A900

Fault of left front wheel speed sensor: its fault causes can’t be definitely known.

C003408

Faults of right front wheel speed sensor signals: off-limit, loss, noises, intermittent
interruptions

C003500

Fault of right front wheel speed sensor wire: open-circuit

C00A200

Fault of right front wheel speed sensor wire: shorted to ground

C00A300

Fault of right front wheel speed sensor wire: shorted to power supply

C00AA00

Fault of right front wheel speed sensor: its fault causes can’t be known.

C003708

Faults of left rear wheel speed sensor signals: off-limit, loss, noises, intermittent
interruptions

C003800

Fault of left rear wheel speed sensor wire: open-circuit

C00A400

Fault of left rear wheel speed sensor wire: shorted to ground

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Brake system 2F-38

DTC fault code

Description of fault codes

C00A500

Fault of left rear wheel speed sensor wire:shorted to the power supply

C00AB00

Faults of Left rear wheel speed sensor:its fault causes can’t be definitely known.

C003A08

Faults of Right rear wheel speed sensor signals: off-limit, loss, noises, intermittent
interruptions

C003B00

Fault of Right rear wheel speed sensor wire: open-circuit

C00A600

Fault of Right rear wheel speed sensor wire: shorted to ground

C00A700

Fault of right rear wheel speed sensor wire:shorted to the power supply

C00AC00

Faults of right rear wheel speed sensor: its fault causes can’t be definitely known.

C109904

Fault of wheel speed sensor set(interchange of wheel speed sensor, overhigh
differences between the wheel speeds, faults of several wheel speed sensor)

C001004

Fault of left front inlet valve

C001104

Fault of left front outlet valve

C001404

Fault of right front inlet valve

C001504

Fault of right front outlet valve

C001804

Fault of left rear inlet valve

C001904

Fault of left rear outlet valve

C001C04

Fault of Right rear inlet valve

C001D04

Fault of right rear outlet valve

C109504

Fault of valve relay

C002004

Fault of return pump motor

C007208

Faults of valve set (overheat protection, disabled signals, hardware damages)

4.2 High or low supply voltage

Fault setting conditions

When the supply voltage of ECU conforms to any of the following conditions, this fault will be produced:

(1) The voltage of vehicle when starting the power-up vehicle is below 4.5V.

(2) When the ignition switch is in On position, the voltage is below 7.7V or above 16.8V.

(3) When the vehicle speed is above 6km/h, the voltage is between 7.7V and 9.2V.

Possible fault causes

(1) Overhigh or overlow voltage of battery.

(2) Damages of ECU.

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Brake system 2F-39

Diagnostic steps

Step Operation

Yes

Is the initial check performed?

Perform Step 2.

Perform the initial

check. (see Page 3)

Measure the voltage of battery. Do you find out the
faults and remove them? For the definitions of pins,
refer to the circuit diagram of detailed items.

Perform Step 4.

Perform Step 3.

Cross validation of ABS (for its detailed steps, refer
to Section “Removal and Installation”). In case of
confirming the damages of ECU, replace ABS. Is the
fault removed?

Perform Step 4.

Re-diagnose it, and confirm whether its fault is
regenerated?

Completion of

diagnostic work

4.3 Faults of solenoid valve and valve set relay

Fault codes: C001004; C001104; C001404; C001504; C001804; C001904; C001C04; C001D04;
C109504; C007208

Fault setting conditions

(1) Valve supply faults.(short circuit of power supply to ground or open circuit of earth wire)

(2) Overhigh temperature of solenoid valve.(overheat protection)

(3) Short circuit of at least 5 solenoid valves(fuses)

(4) Actuate the corresponding solenoid valve, but it has no feedbacks. Diagnostic steps

(5) Self-faults of solenoid valve.

(6) Faults of valve set relay.

Possible fault causes

(1) Short circuit of solenoid valve to power supply or earth, open circuit of wire(poor earthing).

(2) Fuse

faults.

(3) Overheat protection of system (overlong operating time of solenoid valve, which often occurs in case

of vacuum filling and off-line check).

(4) ABS

damages.

Step Operation

Yes

Cool the vehicle for 5 minutes, and check whether its
faults are removed?

Perform Step 2.

Is the initial check performed?

Perform Step 3.

Perform the initial

check.

Measure the voltage of power supply pins of solenoid
valve in connectors, and check the fuses, external
relays, connectors, wires and earth wires. Are the
faults found out and removed? For the definitions of
pins, refer to the circuit diagrams for detailed items.

Perform Step 5.

Perform Step 4.

Cross validation of ABS (for its detailed steps, refer
to Section “Removal and Installation”). In case of
confirming the damages of ABS, replace ABS. Is the
fault removed?

Perform Step 5.

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Brake system 2F-40

Step Operation

Yes

Stop the vehicle after increasing its speed up to
15km/h, re-diagnose it, and confirm whether the fault
is regenerated?

Completion of

diagnostic work

4.4 Fault of pump motor

Fault codes: C002004

Fault setting conditions

(1) Overload operation of pump motor, its overhigh temperature (overheat protection)

(2) After the return pump motor relay works for 60ms, the return pump monitor can’t still detect any

voltage signal.

(3) The return pump motor relay fails to work, and the return pump monitor detects the voltage of over 2.

5V.

(4) The return pump motor relay stops its operation, the return pump monitor detects no reduction of

voltage.

Possible fault causes

(1) Poor grounding of pump motor.

(2) Overheat protection of system.

(3) Abnormality of pump motor power supply(fuse, battery terminal)

(4) Faults of pump motor relay.

(5) Faults of pump motor.

Diagnostic steps

Step Operation

Yes

Cool the vehicle for 5 minutes, and check whether its
faults are removed?

Perform Step 2.

Is the initial check performed?

Perform Step 3.

Perform the

initial check.

Measure the voltage of power supply pins of pump motor
in connectors, and check the fuses, external relays,
connectors, wires and earth wires. Are the faults found
out and removed? For the definitions of pins, refer to the
circuit diagrams for detailed items.

Perform Step 5.

Perform Step 4.

Cross validation of ABS (for its detailed steps, refer to
Section “Removal and Installation”). In case of
confirming the damages of ABS, replace ABS. Is the
fault removed?

Perform Step 5.

Stop the vehicle after increasing its speed up to 15km/h,
re-diagnose it, and confirm whether the fault is
regenerated?

Completion of

diagnostic work

4.5 Wheel speed sensor wire

Fault codes: C003200; C00A000; C00A100; C00A900; C003500; C00A200; C00A300; C00AA00;
C003800; C00A400; C00A500; C00AB00; C003B00; C00A600; C00A700; C00AC00; C109904

Fault setting conditions

(1) ECU detects that the signal line of wheel speed sensor is shorted to ground.

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Brake system 2F-41

(2) Open circuit of wheel speed sensor wire.

Possible fault causes

(1) Disconnection, loosened connection or fracture of wheel speed sensor wires.

(2) Reverse connection of wheel speed sensor signal line and power line.

(3) Short circuit of signal line to ground.

(4) Damages of sensor head or connection pin.

Diagnostic steps

Step Operation

Yes

Is the initial check performed?

Perform Step 2.

Perform the

initial check.

Check whether the wheel speed sensor is perfectly
connected. Check the open circuit or short circuit of wheel
speed sensor wires in the harness. Are the faults found out
and removed? For the definitions of pins, refer to the
circuit diagrams for detailed items.

Perform Step 4. Perform Step 3.

Cross validation of ABS (for its detailed steps, refer to
Section “Removal and Installation”). In case of confirming
the damages of ABS, replace ABS. Is the fault removed?

Perform Step 4.

Stop the vehicle after increasing its speed up to 15km/h,
re-diagnose it, and confirm whether the fault is
regenerated?

Completion of

diagnostic work

4.6 Faults of wheel speed sensor signals

Fault codes: C003108; C00A900; C003408; C00AA00; C003708; C00AB00; C003A08; C00AC00;
C109904

Fault setting conditions

(1) ECU detects that the signal line of wheel speed sensor is shorted to the power supply.

(2) ECU detects that the power line of wheel speed sensor is shorted to ground.

(3) Abnormal signals of wheel speed sensor.

Possible fault causes

(1) Disconnection, loosened connection or breakage of wheel speed sensor wires.

(2) The signal line of wheel speed sensor is shorted to the power supply.

(3) The power line of wheel speed sensor is shorted to ground.

(4) Non-installation of gear ring, loss of teeth, dirty gear ring, existence of strange substances,

demagnetizing, eccentric gear ring.

(5) Excessive air gap between the sensor and gear ring.

(6) External magnetic field interference of wheel speed sensor (demagnetizing failure of wheel or axle).

(7) Faults of wheel speed sensor body.

(8) Wrong number of gear ring teeth.

(9) Above-normed size of tire.

(10) Damages of ECU.

Diagnostic steps

Note:

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Haima S5. Chassis System. Instruction - part 6