Haima S5 1.5T. Chassis System. Service Manual

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.:

MC1 First circuit of brake master cylinder

Right rear wheel

MC2 Second circuit of brake master cylinder

FLEV

left front wheel oil inlet valve

motor

FLAV

left front wheel oil outlet valve

RP1

return pump 1

FREV

right front wheel oil inlet valve

RP2

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 manual.

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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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 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-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 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-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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Haima S5 1.5T. Chassis System. Service Manual - part 6