Haima M3. Chassis System. Service Manual

Brake system 2F-40

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-41

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-42

(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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Brake system 2F-43

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-44

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 manually 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 manual pedal.

3. Combined exhaustion of manual 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-45

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 Manual 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 manual 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-46

values.

Remarks:



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

Technical parameters for repair

Vehicle type

Haima M3

Models of brake fluid

DOT4
DOT4+
Super DOT4+ DOT5. 1

Number of front axle gear ring teeth

Number of rear shaft gear ring teeth

Tire model

185/60 R15

Spare tire model

The same as model of tire

Repair manual for Haima NA01 ESP 9

Customer:
Vehicle type:

Haima
M3

Product system:
Types of brake circuit arrangements:
Drive type:

ESP 9
Arrangement of X circuit
Front wheel drive

Diagnostic specifications:
Communication type:

KWP2000
CAN



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

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Brake system 2F-47

Summary

I. Attentions

ESP 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. ESP system must be repaired by trained and

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

2. Before diagnosing ESP 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. ESP assembly (e.g. ESP 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 ESP assembly, and undertake
no responsibility for bad consequences caused
after disassembling or partially
replacing/interchanging ESP hydraulic
regulator.

4. The following two cases indicate that ESP

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 ESP sensor wires:

●

Before pulling down ESP 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 ESP wires must be installed

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

While connecting ESP brake pipe, be sure

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

cases:

● After the speed of vehicle is increased up to

40km/h, it will produce a short sound of
“buzz”, this is a sound of starting the return
pump motor during ESP self-check, which is a
normal phenomenon.

● After the speed of vehicle is increased up to

30km/h and the volume of brake fluid in the
energy accumulator reaches a certain value,
ESP return pump motor will start and produce
a sound of “buzz”;

● After the vehicle drives continually for 500

min, it will start ESP return pump motor to
return the brake fluid accumulated in the
energy accumulator, and produce a sound of
“buzz”;

● ESP 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 ESP hydraulic unit.

2) Sound caused by the bounce of brake pedal.

3) Impact sound of suspension and body caused

by emergency braking operation.

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Brake system 2F-49

II. Initial

check

Before the diagnosis of ESP system, first check its
parts, which may cause the faults of ESP 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 ESP hydraulic regulator, brake pipe and

connections for leakage.

3. Check the fuses of ESP system ensure that no

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

●

Pump motor fuse (40A)

●

Solenoid valve fuse (25A)

●

Electronic control unit fuse (5A)

4. Check the voltage of battery, and check

whether the battery terminals are corroded or
loosened.

Normal operating voltage range of ESP system is
9.3V-16.8V.

5. Check whether the bonding point of ESP earth

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

6. ESP earth wire must have good sealing ability

to prevent the water or moisture from
penetrating into ESP 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

ESP 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.

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-50

● ESP 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. ESP 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, ESP can’t
prevent the vehicle from slipping fully, too.

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

caused by the following cases:

● Loosened fixation of ESP assembly and

support.

● Loosened fixation of ESP support and vehicle

body.

● Loss or damages of plastic washers on ESP

support.

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Brake system 2F-51

Introduction of ESP 9 system

I. Composition of ESP 9 system

As shown in the figure below, ESP 9 consists of hydraulic module with an electronic control unit and
sensors.

①

ESP hydraulic control module (integrated yaw rate sensor) with an electronic control unit

②

Wheel speed sensor

③

Steering wheel angle sensor

④

Communications with engine management system

Note: this drawing is only for reference. For the detailed positions of elements, please refer to the vehicle
maintenance manual.

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Brake system 2F-52

II. Hydraulic diagram for ESP 9

The brake system of this vehicle is arranged in X shape. As shown in the figure below, ESP 9 hydraulic
regulator includes a motor, two return pumps, two energy accumulators and twelve solenoid valves.

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-54

Definitions of ECU pins

Pin Function

Motor power terminal(positive pole)

Wheel speed sensor output(unused)

3 EBD

warning

lamp

4 Wheel speed sensor signal

terminal(right front)

5 Undefined

6 Diagnostic

line(unused)

7 Undefined

Wheel speed sensor signal terminal (left
front)

9 Undefined

10 Speed

output

11 Undefined

ESP OFF switch

13 motor

ground

end

CAN1 l (CAN1 low)

15 Undefined

Wheel speed sensor power
terminal(right front)

Wheel speed sensor power
terminal(right rear)

18 Wheel speed sensor signal terminal(left

rear)

Wheel speed sensor power terminal(left
front)

Function

Undefined

ESP OFF indicator lamp

Undefined

Valve relay power terminal

CAN1h (CAN1 high)

Undefined

ECU power terminal(ignition power line)

Wheel speed sensor signal terminal(right
rear)

Brake lamp switch

Wheel speed sensor power terminal(left
rear)

Undefined

ABS warning lamp

ESP multi-functionindicator lamp

Undefined

ECU ground end

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Brake system 2F-55

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 M3. Chassis System. Service Manual - part 7