Haima S5. Chassis System. Instruction

Brake system 2F-42

1) For the faults of wheel speed sensor signals, after removing the faults, be sure to start the vehicle and

increase its speed up to about 15km/h, thus ABS warning lamp can go out.

2) Don’t measure the supply voltage from the wheel speed sensor to ECU. Once the open circuit of

wheel speed sensor exists, ECU will stop its power supply automatically, until its power supply is
recovered after the next ignition self-check.

4.7 ECU faults

Fault codes: C100004; C101008

Fault setting conditions

(1) ECU supply fault.

(2) Damages of ECU.

Possible fault causes

ECU faults

Diagnostic steps

Step Operation

Yes

Is the initial check performed?

Perform Step 2.

Perform the initial

check.

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 3.

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

Completion of

diagnostic work

4.8 Unreasonable control of ABS

Fault codes:C006B06

Fault setting conditions

ABS receives the command of continual operation (above 1 minute).

Possible fault causes

(1) Continual braking of ice.

(2) Overlarge

wheel

speed difference.

Diagnostic steps

Step Operation

Yes

Is the initial check performed?

Perform Step 2.

Perform the

initial check.

Check the wheel speed sensor and gear ring. Are the
faults removed?

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 the fault is
regenerated?

Completion of

diagnostic work

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Brake system 2F-43

Removal and installation

I. Steps for removing ABS assembly

1. Make the ignition switch in OFF position, and disconnect the negative pole of battery.

2. Remove the wire from ABS assembly.

3. Step the brake pedal to bottom, fix it with a pedal support to prevent the brake fluid from flowing out

after removing the brake pipe from the brake master cylinder.

4. Remove the brake pipe, block the thread hole of ABS assembly and oil hole of brake pipe to avoid the

entry of impurities.

5. Take down ABS from the fixed support.

II. Installation steps of ABS assembly

1. Install ABS assembly on the support,and tighten it up to the torque of 8±2Nm.

2. Take down the plugs from ABS thread hole and brake pipe, connect the brake pipe into ABS assembly,

and tighten it up to the torque of 16±2Nm.

3. Add the brake fluid into fluid reservoir up to Max, and bleed it as per the specified method.

III. Cross validation

1. Remove ABS to install it on another vehicle with the same model and without faults (the oil pipe can’t

be installed, and only ECU plug is connected, but you must ensure that the plug can’t be loosened
while the vehicle is driving).

2. Drive the vehicle, ensure the vehicle speed is not below 20km/h, and activate the dynamic self-check

of ABS.

IV. Exhaust instructions

The hydraulic unit can be instructionly exhausted, and any of following three exahust procedures can be
selected during the repair:

1. Exhaust with a filling unit (exhaust pressure of 2bar).

2. Exhaust with a instruction pedal.

3. Combined exhaustion of instruction pedal and filling unit.



After the customer replaces the brake system (e.g. replacement of brake fluid, brake pipe or hydraulic
unit), or the brake pedal is soft, it must be exhausted.



The hydraulic unit replaced by the customer must be a filled ABS hydraulic regulator with ECU.



During the exhaustion, be sure to ensure the complete structure of brake system, and all the high-
pressure hydraulic units have been connected.



It’s required to pull the parking brake before exhausting it.



The brake fluid is corrosive. If it’s affixed to the skin carelessly, it must be removed.

4.1 Exhaust with an exhaustion/filling unit (exhaust pressure of 2 bar).

Connect the exhaust/filling unit to the fluid reservoir, confirm that the brake fluid is enough to

turn on the switch, and set its pressure to 2bar.

Open the bleed screw on the wheel cylinder, until all the air bubbles are drained.

Check the stroke of pedal.

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Brake system 2F-44

If not successful, exhaust it again at each wheel.

Check the level of brake fluid, and ensure that it’s between the maximum and minimum

values.

4.2 Instruction pedal exhaustion

Fill up the fluid reservoir(up to the neck of filter)

Repeat the following procedures for each wheel cylinder. Air exhaustion sequence: left rear,

left front, right front, right rear

Open the bleed screw.

Repeat stepping the brake pedal.

Close the exhaust screw.

Loosen the brake pedal.

Check the stroke of pedal.

If not successful, exhaust it again.

Check the level of brake fluid, and ensure that it’s between the maximum and minimum

marks.

4.3 Combination of instruction pedal exhaustion and 2 bar exhaustion

Connect the exhaust/filling unit to the fluid reservoir, confirm that the brake fluid is enough to

turn on the switch, and set its pressure to 2bar.

Open the bleed screw on the wheel cylinder, until all the air bubbles are drained.

Sequence: left rear, left front, right front, right rear

Repeat stepping the pedal back and forth.

Check the stroke of pedal.

If not successful, exhaust it again at each wheel.

Check the level of brake fluid, and ensure that it’s between the maximum and minimum

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Brake system 2F-45

values.

Remarks:



Recommended sequence of X circuit: Left rear, left front,right front, right rear.



In the whole exhaustion, the level of brake fluid in fluid reservoir can’t be below its lowest mark.

Technical parameters for repair

Vehicle type

Haima M3

Models of brake fluid

DOT4

Number of front axle gear ring teeth

Number of rear shaft gear ring teeth

Tire model

215/65 R16 or 215/60 R17

Spare tire model

The same as model of tire

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Brake system 2F-47

Summary

I. Attentions

ESC 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. ESC system must be repaired by trained and

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

2. Before diagnosing ESC system, if the

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

●

Brake system noises

● Overhard

brake

pedal.

● During the common braking operation,the

brake pedal or vehicle vibrates.

●

Runout of vehicle brake.

●

Faults of parking brake system

3. ESC assembly (e.g. ESC 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 ESC assembly, and undertake
no responsibility for bad consequences caused
after disassembling or partially
replacing/interchanging ESC hydraulic
regulator.

4. The following two cases indicate that ESC

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 ESC sensor wires:

● Before pulling down ESC wire and sensor

wire, be sure to disconnect the ignition switch.

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Brake system 2F-48

● Ensure the drying and cleanness of

connector,and avoid the entry of any strange
substance .

● The connectors of ESC wires must be installed

in position in horizontal and vertical directions
to avoid their damages.

While connecting ESC brake pipe, be sure

to ensure its correct installation. ESC 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 ESC 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. ESC will produce the noises in the following

cases:

● After the speed of vehicle is increased up to

30km/h, it will produce a short sound of
“buzz”, this is a sound of starting the return
pump motor during ESC self-check, which is a
normal phenomenon.

● ESC will produce the noises during the normal

operation, which is mainly reflected by the
following aspects:

1) Action sound of motor, solenoid valve and

return pump in ESC hydraulic unit.

2) Sound caused by the bounce of brake pedal.

3) Impact sound of suspension and body caused

by emergency braking operation.

II. Initial

check

Before the diagnosis of ESC system, first check its
parts, which may cause the faults of ESC 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

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Brake system 2F-49

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 ESC hydraulic regulator, brake pipe and

connections for leakage.

3. Check the fuses of ESC system ensure that no

fuses are burnt and their models are correct.
ESC 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 ESC system is
9.3V-16.8V.

5. Check whether the bonding point of ESC earth

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

6. ESC earth wire must have good sealing ability

to prevent the water or moisture from
penetrating into ESC 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

ESC 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 produce the sensing noises, thus it
will disturb the normal operation of circuit.

● ESC 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. ESC 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

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

Hydroplaning

Water line

Don’t cling.

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Brake system 2F-51

Introduction of ESC system

I. Composition of ESC system

As shown in the figure below, ESC charged by the hydraulic control unit module, airbag ECU and various
sensors. ESC control program, the yaw rate sensor is integrated in the airbag ECU, each of the wheel speed
signal through a hard line, the steering angle signal is input to the airbag ECU via CAN line, hydraulic
control unit ECU receives signals internal airbag ECU via CAN line

II. Hydraulic diagram for ESC

The brake system of this vehicle is arranged in X shape. As shown in the figure below, ESC hydraulic
regulator includes a motor, two return pumps, two energy accumulators and twelve solenoid valves.

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Brake system 2F-52

The following meanings of English abbreviations in Fig.:

MC1

First circuit of brake master cylinder

FLAV Left

front

wheel outlet valve

MC2

Second circuit of brake master
cylinder

FREV

Right front wheel inlet valve

Motor

FRAV

Right front wheel outlet valve

RP1

Return pump 1

RLEV

Left rear wheel inlet valve

RP2

Return pump 2

RLAV

Left rear wheel outlet valve

Energy accumulator 1

RREV

Right rear wheel inlet valve

Energy accumulator 2

RRAV

Right rear wheel outlet valve

Left front wheel

HSV1

High-pressure valve 1

Right front wheel

HSV2

High-pressure valve 2

Left rear wheel

USV1

Guide valve 1

Right rear wheel

USV2

Guide valve 2

FLEV

Left front wheel inlet valve

P/U

Pressure gauge

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Brake system 2F-57

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: ignite to start the vehicle again, accelerate the vehicle
speed up to 15km/h, and read the faults again.

Faults

Go to Step 7

No faults

Go to Step 8

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.

For the occassional fault, repair and then go to Step 9.

Confirm the removal of faults.

Avoid the regeneration of faults.

Conclusion

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Haima S5. Chassis System. Instruction - part 7