Руководство для хайма 3

2. Эксплуатация

Индикаторы на щитке приборов

	Индикатор тормозной системы
	Индикатор стояночного тормоза
	Индикатор давления масла в двигателе
	Индикатор низкого уровня топлива
	Индикатор ремня безопасности водителя
	Индикатор системы подушек безопасности
	Индикатор электронной системы курсовой устойчивости
	Индикатор разряда аккумуляторной батареи
	Указатель поворота налево
	Указатель поворота направо
	Индикатор аварийной температуры охлаждающей жидкости
	Индикатор неисправности двигателя
	Индикатор антиблокировочной системы тормозов
	Индикатор дальнего света фар
	Индикатор давления в шинах (опция)
	Индикатор передних противотуманных фар
	Индикатор задних противотуманных фонарей

Действия в случае срабатывания индикаторов

Если загорается индикатор или срабатывает зуммер	Действия
(а)		Остановиться в безопасном месте и обратиться в авторизованный сервисный центр HAIMA.
(b)		Остановиться в безопасном месте и проверить уровень масла. При необходимости обратиться в авторизованный сервисный центр HAIMA.
(с)		Остановиться в безопасном месте и обратиться в авторизованный сервисный центр HAIMA.
(d)		Пристегнуть ремень безопасности водителя.
(е)		Пристегнуть ремень безопасности пассажира.
(f)		Обратиться в авторизованный сервисный центр HAIMA.
(g)		Если индикатор загорелся и не погас после третьего выключения зажигания, обратиться в авторизованный сервисный центр HAIMA.
(h)		Заправить топливо.
(i)		Обратиться в авторизованный сервисный центр HAIMA.
(j)		Если переключатель TCS не выключен и загорается индикатор ESC, возможна неисправность системы ESC. Обратиться в авторизованный сервисный центр HAIMA.
(k)		Закрыть все двери.
(m)	Зуммер сигнализации о ключе в замке зажигания	Извлечь ключ.
(n)	Зуммер сигнализации о включенном освещении	Выключить освещение.

(a), (b), (c), (d) Если ремень безопасности не пристегнут при скорости движения выше 25 км/ч, на 30 секунд срабатывает зуммер. Если в течение 30 секунд пристегнуть ремень, сигнал прекратится. При скорости ниже 25 км/ч начнется новый отсчет, и через 30 секунд зуммер сработает снова. Затем сигнал зуммера повторно не срабатывает.
(e) Индикатор непристегнутого ремня безопасности пассажира

Индикатор горит до тех пор, пока пассажир не пристегнет ремень безопасности после поворота ключа в замке зажигания в положение «ON» («ВКЛ.») или «START» («ЗАПУСК»).
(f) Индикатор системы подушки безопасности

Индикатор загорается при переводе ключа в замке зажигания в положение «ON» («ВКЛ.»). Он выключается приблизительно через 6 секунд. Это указывает на нормальное функционирование системы подушек безопасности. Приведенные ниже признаки указывают на неисправность элементов, контролируемых индикаторной схемой. Требуется проведение осмотра автомобиля в авторизованном сервисном центре HAIMA.
— При переводе ключа в замке зажигания в положение «ON» индикатор не загорается или горит непрерывно.
— Индикатор горит или мигает при управлении автомобилем.
Внимание:
Запрещается самостоятельно проводить ремонт или демонтаж подушки безопасности. При самостоятельном ремонте или демонтаже подушки безопасности может произойти ее внезапное раскрытие или отказ системы, что может привести к травме или смертельному исходу.
(g) Индикатор неисправности двигателя

Индикатор указывает на неисправность систем двигателя или превышение уровня выхлопных газов. Индикатор загорается в следующих случаях:
a) в топливном баке нет топлива;
b) при неисправности двигателя, автоматической трансмиссии или электронной системы впрыска топлива.
Если индикатор загорается в случае b во время управления автомобилем, рекомендуется в кратчайшие сроки обратиться в авторизованный сервисный центр HAIMA для проведения осмотра или ремонта. Если индикатор загорается после трехкратного отключения зажигания, обратитесь в авторизованный сервисный центр HAIMA.
Примечание:
Запрещается управлять автомобилем на большой скорости даже после отключения индикатора.
(h) Индикатор низкого уровня топлива

Индикатор загорается при низком уровне топлива в баке. Необходимо как можно скорее заправить бак.
При движении на уклоне или в повороте индикатор низкого уровня топлива может загораться раньше из-за перемещения топлива вбаке.
(i) Индикатор ABS (антиблокировочной системы тормозов)

Индикатор ABS включается при переводе ключа в замке зажигания в положение «ON» («ВКЛ.»). При нормальном функционировании антиблокировочной системы через несколько секунд индикатор отключается. В случае неисправности системы индикатор ABS снова загорается.
Если горит индикатор ABS (индикатор тормозной системы не горит), ABS не работает, но тормозная система функционирует нормально. Таким образом, при экстренном торможении или торможении на мокром дорожном покрытии колеса могут блокироваться и скользить.
Приведенные ниже признаки указывают на неисправность элементов, контролируемых индикатором. Незамедлительно обратитесь вавторизованный сервисный центр HAIMA для проверки автомобиля.
— Индикатор не загорается или горит непрерывно при переводе ключа в замке зажигания в положение «ON» («ВКЛ.»).
— Индикатор загорается или мигает при управлении автомобилем.
Внимание:
Если одновременно загораются индикатор ABS и индикатор тормозной системы, рекомендуется съехать с дороги и обратиться в авторизованный сервисный центр HAIMA. В этом случае нарушается работа ABS, автомобиль становится чрезвычайно неустойчивым при торможении.
Периодическое включение индикатора не указывает на неисправность при управлении автомобилем.
(j), (k) Индикатор незакрытых дверей

Если дверь открыта или закрыта неплотно, загорается данный индикатор.
(m) Зуммер сигнализации о ключе в замке зажигания
При выключенном двигателе и открытой двери водителя зуммер напоминает о том, что необходимо вынуть ключ из замка зажигания.
(n) Зуммер сигнализации о включенном освещении
Если при выключенном двигателе и вынутом ключе зажигания дверь со стороны водителя открыта, а свет в салоне не выключен, зуммер напоминает о включенном выключателе освещения.
(m) Индикатор давления в шинах

В случае отклонения значения давления воздуха в системе контроля давления в шинах (TPMS) от нормы датчик TPMS сигнализирует об этом непрерывно горящим индикатором давления в шинах при включенном зажигании.
Переключение дисплея одометра/счетчика пробега за одну поездку
При нажатии кнопки дисплеи переключаются.

Одометр

Показывает общее расстояние, пройденное автомобилем.

Счетчики пробега за одну поездку (А и В)

Счетчик отображает расстояние, пройденное автомобилем с момента последнего сброса показаний. Счетчики пробега за одну поездку (А и В) можно использовать независимо друг от друга для записи и показа различных расстояний. Для сброса показаний нажмите и удерживайте кнопку.

Кнопка регулятора подсветки приборной панели

Яркость подсветки приборной панели можно отрегулировать, нажав кнопку.
При этом ключ в замке зажигания находится в положении «ON».

Яркость подсветки приборной панели

Когда включены задние габаритные фонари, яркость подсветки приборов слегка уменьшится, если только ее уровень был установлен на максимальную величину. Если задние габаритные фонари включаются при наступлении темноты, яркость контрольных приборов немного уменьшается. Однако при ярком свете снаружи, например в дневное время, яркость контрольных приборов не уменьшится даже при включении задних габаритных фонарей.

Отображение уровня топлива при активном режиме одометра / счетчика пробега

После переведения ключа в замке зажигания в выключенное положение указатель уровня топлива в баке и дисплей одометра/счетчика пробега остаются включенными в течение 10 минут, что позволяет повторно проверить показания указателя уровня топлива в баке и одометре/счетчике пробега, не переводя ключ в замке зажигания в положение «ON».
Внимание:
Для предотвращения повреждения двигателя и его компонентов не допускайте, чтобы стрелка индикатора тахометра перемещалась в красную зону, что сигнализирует о максимально возможном числе оборотов двигателя. Двигатель может перегреться, если мигает крайний правый сегмент дисплея температуры охлаждающей жидкости двигателя. В этом случае немедленно остановите автомобиль в безопасном месте и проверьте двигатель после его полного охлаждения.

Clutch System 2A-1
Volume II Chassis System
Chapter 10 Clutch System........................................................................................................................2A-1
Chapter 11 List of tires and drive shafts................................................................................................... 2B-1
Chapter 12 Wheels and tires..................................................................................................................... 2C-1
Chapter 13 Suspension system.................................................................................................................2D-1
Chapter 14 Steering system...................................................................................................................... 2E-1
Chapter 15 Brake system.......................................................................................................................... 2F-1
Clutch System 2A-1
Chapter 10
Clutch System
Basic steps.................................................................................................................................................2A-2
Removal/installation of clutch oil pipe .............................................................................................2A-2
Cluch pedal................................................................................................................................................2A-2
Check of clutch pedal........................................................................................................................2A-2
Free stroke of clutch pedal ................................................................................................................2A-2
Decoupling point of clutch pedal ......................................................................................................2A-2
Release stroke of clutch pedal...........................................................................................................2A-2
Removal/installation of clutch pedal.................................................................................................2A-2
Mounting instructions for clutch pedal .............................................................................................2A-4
Clutch master cylinder ..............................................................................................................................2A-4
Removal/installation of clutch master cylinder.................................................................................2A-4
Disassembly/assembly of clutch master cylinder..............................................................................2A-5
Instructions for disassembly/assembly of position-limiting seat.......................................................2A-6
Clutch slave cylinder.................................................................................................................................2A-6
Removal/installation of clutch slave cylinder ...................................................................................2A-6
Disassembly/assembly of clutch slave cylinder ................................................................................2A-6
Clutch device.............................................................................................................................................2A-7
Check of clutch release bearing ........................................................................................................2A-7
Instructions for removal of clutch pressure plate and friction plate ..................................................2A-7
Instructions for removal of guide bearing .........................................................................................2A-7
Instructions for flywheel removal .....................................................................................................2A-7
Mounting instructions of flywheel ....................................................................................................2A-7
Mounting instructions for guide bearing ...........................................................................................2A-7
Mounting instructions for clutch friction plate..................................................................................2A-8
Mounting instructions for clutch pressure plate ................................................................................2A-8
Check of clutch pressure plate ..........................................................................................................2A-8
Check of clutch friction plate ............................................................................................................2A-8
Check of clutch release bearing ........................................................................................................2A-9
Check of guide bearing .....................................................................................................................2A-9
Mounting instructions for clutch pressure plate ................................................................................2A-9
Flywheel....................................................................................................................................................2A-9
Check of flywheel .............................................................................................................................2A-9
Clutch System 2A-2
Free stroke of pedal: 5 to 14mm (0. 2 to 0. 55in)
Basic steps
Removal/installation of clutch oil pipe
Note
Free stroke of pedal
●
The oil reservoir is shared by the clutch and
brake system.
1.
Provided the clutch is disassembled in any
case, add in the clutch oil (brake oil) and
drain the air, check the oil for leakage after
installing the clutch.
Decoupling point of clutch pedal
1.
Disassemble the clutch oil pipe with a special
tool, i.e. double open end wrench, and
assemble it together with a torque connecting
rod and above tool.
Apply the parking brake, and pack the mat
wood under front and rear wheels.
2.
Start the engine, and make it idling.
3.
Ensure that the clutch flange nut shall be
tightened up to the specified torque.(refer to
the basic steps, torque and specifications)
Don’t step the clutch pedal, and put the gear
lever slowly in reverse gear.
4.
In case of hearing the gear noises, keep the
gear lever in position.
5.
Step down the clutch pedal slowly.
6.
When the noises of gear disappears, keep the
clutch pedal unchanged (decoupling point of
clutch pedal).
7.
Measure the distance a (pedal stroke until the
clutch pedal decoupling point is fully stepped
down) and pedal stroke.
8.
Confirm the release stroke is within the
specified value.
2.
3.
Cluch pedal
Check of clutch pedal
Measure the distance from upper surface of clutch
pedal rubber to the carpet.
●
If incorrect, check whether the clutch pedal is
wrongly assembled.
206- 212mm (8. 11- 8. 35in) (for reference)
If it’s outside the specified value, check whether
the clutch pedal and clutch master cylinder are
correctly assembled, and drain the air out of
clutch pipe.
Release stroke of clutch pedal
102.5 to 110.5(4.04 to 4.35in) (for reference)
Pedal stroke: 116mm (4.57in) (for reference)
Height of pedal
Release point
of clutch pedal
Free stroke of clutch pedal
Measure the free stroke of clutch. The free stroke
of clutch pedal is the distance required until a
resisting force is felt by pressing down the clutch
pedal by hands.
●
If incorrect, check whether the clutch pedal is
wrongly assembled.
Pedal stroke
Removal/installation of clutch pedal
1.
Remove the air filter (refer to its external
Clutch System 2A-3
accessories, removal/installation of air filter).
2.
Remove the battery and its cover.
3.
Disassemble as per the shown sequence.
4.
Assemble it in the reverse sequence of
removal.
5.
After installing it, check the clutch pedal
again (refer to the check of clutch pedal).
1
Lock nut
2
Split pin
3
Pin shaft
4
Clutch master cylinder
5
Clutch pedal assembly(refer to its mounting instructions)
6
Clutch hose
7
Pedal rubber mat
Clutch System 2A-4
Mounting instructions for clutch pedal
After installing it, adjust the height and free stroke
of pedal (refer to the check of clutch pedal).
Clutch master cylinder
Removal/installation of clutch master
cylinder
1.
Disassemble the air filter (refer to its external
accessories, removal/installation of air filter).
2.
Disassemble the battery and its cover.
1
Lock nut
2
Split pin
3
Mineshaft
4
Clutch oil pipe
5
Elastic clamp
6
Clutch master cylinder
7
Clutch pedal assembly
8
Clutch hose
3.
Disassemble them in the shown sequence.
4.
When removing the oil pipe, immediately
choke it up with a plug to avoid the oil
leakage.
5.
Install it in the reverse sequence of removal.
Clutch System 2A-5
Disassembly/assembly of clutch master cylinder
1.
Disassemble it in the shown sequence.
2.
Assemble it in the reverse sequence of disassembly.
1
Snap ring
2
Clamp
3
Clutch oil inlet hose
4
Position-limiting seat
5
O ring
6
Pushrod assembly
7
Piston seat
8
Secondary cup
9
Limit mat
10
Primary cup
11
Piston
12
Compensation pad
13
Bush
14
Washer
15
Cylinder body
Clutch System 2A-6
Instructions for disassembly/assembly of
position-limiting seat
Draw back the pour card of position-limiting seat
inside with a special tool to remove the positionlimiting seat and piston.
●
During the disassembly, remove the positionlimiting seat; during the assembly, install the
position-limiting seat.
Clutch slave cylinder
Removal/installation
cylinder
of
clutch
slave
1.
Remove the mudguard.
2.
Remove it in the shown sequence.
3.
Install it in the reverse sequence of removal.
1
Snap spring
2
Clutch pipe
3
Bolt
4
Clutch slave cylinder
Disassembly/assembly
cylinder
of
clutch
slave
1.
Disassemble it in the shown sequence.
2.
Assemble it in the reverse sequence of
disassembly.
1
Piston stopper
2
Shield
3
Piston assembly
4
Leather cup
5
Spring seat
6
Spring
7
Dust cap
8
Bleed screw
9
O ring
10
Bleed screw gasket
11
Bush
12
Snap ring
13
Cylinder body
Clutch System 2A-7
SST (as shown in the figure).
Clutch device
Check of clutch release bearing
Note
●
While cleaning the release bearing with
cleaning oil or vapor detergent, remove the
grease sealed in the bearing.
1.
Turn the release bearing hardly in axial
direction.
●
If the bearing can’t be turned or meets its high
resisting force, replace the clutch release
bearing in case of abnormal noises.
2.
Install it in the reverse sequence of removal.
2.
3.
1.
Lock the flywheel with a special tool SST(as
shown in the figure).
2.
Disassemble the mounting bolt evenly in the
cross sequence.
3.
Disassemble the flywheel.
1
Clutch slave cylinder
2
Manual transmission
3
Protection cover
4
Clutch release bearing
5
Clutch release fork
6
Clutch assembly
Mounting instructions of flywheel
7
Clutch friction plate
1.
Install the flywheel on the crankshaft.
8
Guide bearing
2.
9
Flywheel
Before installing the bolt, clean its threads
and apply the sealant to its threads.
Instructions for removal of clutch
pressure plate and friction plate (see the
details of HM483Q engine repair manual)
1.
Instructions for flywheel removal
Attach the special tool SST(as shown in the
figure).
Loosen the bolt at a time in cross mode, until
its spring pressure is released.
Note
●
In case of applying the new bolt, don’t apply
the sealant to it.
3. Pre-tighten the lock bolt of flywheel by hands.
4.
Install the special tool SST on the flywheel
(as shown in Figure).
5.
Tighten the lock bolt gradually in the cross
sequence.
Disassemble the clutch pressure plate and
friction plate.
Mounting instructions for guide bearing
Instructions for removal of guide bearing
Note
●
The guide bearing shall not be commonly
removed, unless it needs to be replaced.
Remove the guide shaft with a special tool
Note
●
Install the guide bearing as per the
instructions below. Installed depth of guide
bearing
0 - 0.4mm (0-0.115in)
Clutch System 2A-8
Flywheel
Guide bearing
1.
Install the new guide bearing with a special
tool SST (as shown in Fig.).
Mounting instructions for clutch friction
plate
1.
2.
Measure the flatness of pressure plate with a
ruler and thickness gauge.

If above-normed, replace the clutch assembly.
Max. clearance 5mm(0. 02in)
3.
Apply the dial indicator when checking the
diaphragm spring.
4.
Turn the flywheel to check the axial runout of
diaphragm.

If above-normed, replace the clutch pressure
plate.
Axial runout≤0.6mm(0. 024in)
Keep the position of clutch friction plate with
a special tool SST (as shown in Fig.).
Check of clutch friction plate
1.
Measure the depth of rivets to friction plate
surface with a vernier gauge.

If above-normed, replace the clutch friction
plate with depth≤0.3mm(0.01in).
2.
Measure the axial runout of clutch friction
plate with a dial indicator.

If above-normed, replace the clutch friction
plate.
Mounting instructions for clutch pressure
plate
1.
Install the special tool SST(as shown in Fig.).
2.
Tighten the bolt evenly in the cross sequence.
Check of clutch pressure plate
1. Measure the wears of diaphragm spring.

If above-normed, replace the clutch pressure
plate.
Depth<0.6mm (0.024in )
Axial runout ≤ 0.7mm (0.028in)
Clutch System 2A-9
Check of clutch release bearing
Note
●
While cleaning the release bearing with
cleaning oil or vapor detergent, remove the
grease sealed in the bearing.
Turn the release bearing hardly in axial direction.
●
If the bearing can’t be turned or meets its high
resisting force, replace the clutch release
bearing in case of abnormal noises.
Mounting instructions for clutch pressure
plate
1.
Install the special tool SST (as shown in Fig.).
2.
Tighten the bolt evenly in the cross sequence.
Flywheel
Check of flywheel
1.
Install the dial indicator on the cylinder body.
2.
Measure the axial runout of flywheel.

If above-normed, replace the flywheel.
Axial runout≤0.2mm (0. 0084in)
Check of guide bearing
Don’t disassemble the guide bearing, and turn the
bearing hardly in axial direction.

If the bearing can’t be turned or meets its high
resisting force, replace the clutch release
bearing in case of abnormal noises.
List of tires and drive shafts 2B-1
Chapter 11 List of tires and drive shafts
Common procedures ............................................................................................................................... 2B-2
Description and operation ...................................................................................................................... 2B-2
Diagnostic data and procedures............................................................................................................. 2B-4
List of tires and drive shafts 2B-2
Common procedures
Attentions for wheels and tires
Removal and installation of wheels and tires
The removal and installation steps of wheels and
tires are not mentioned in this section. In case of
removing the wheels, their tightening torque is
100-120N.m {10-12.0kgf.m, 73.5-88ft.lbf} during
the installation.
Keypoints for removal of lock nut
1.
Hit the flattening of lock nut out with a small
chisel and hammer.
2.
Apply a braking force to lock the hub.
3.
Remove the lock nut.
Fabric
4.
As shown in figure, insert a crowbar between
right drive shaft and transmission drive axle,
and disengage the drive shaft from the
transmission drive axle.
Keypoints for installation of snap ring
Keypoints for mounting the lock nut
1.
Apply a braking force to lock the nut.
2.
Install the new lock nut up to fixed torque of
300-350N.m {30-35.0kgf.m, 219-255.5ft.lbf}.
At the fixed torque, first hit it up to the
specified torque before loosening it, and hit it
up to the specified torque again.
3.
1. Attach a new snap ring to the connecting shaft,
make its opening up, and ensure that the
diameter of snap ring shall not exceed the
value specified in technical requirements for
installation.
2.
Flatten the lock nut as per the shown
requirements.
After installing the snap ring, measure its
outer diameter. In case of exceeding the value
specified
in
technical
requirements,
additionally renew the snap ring and repeat
Steps 1& 2.
Technical requirements for snap
ring outer diameter snap ring
Snap ring
0.5mm(0.2in)
or above
Opening
Outer diameter
Drive shaft
Keypoints for removal of right drive shaft and
drive axle
1.
Remove the riveting bolt and nut.
2.
Wrap the cloth on the ball joint dust cover.
3.
Pry down the lower swing arm from steering
knuckle.
Check of drive shaft
1.
Check the dustproof rubber sleeve of drive
shaft for cracks or damages, grease for
leakage or hoop for loosening.
2.
Check the drive shaft for bends or cracks,
universal joint or spline for wears. If
necessary, repair or replace the drive shaft
List of tires and drive shafts 2B-3
and dustproof rubber sleeve or hoop.
Therefore, first remove the axle end of ABS
wheel speed sensor, place it in appropriate
position, and ensure it can’t be wrongly
pulled during the repair of car.
2.
Removal and installation of drive shaft
1
2
3
4
5
6
7
①. Drain all the oil out of transmission drive axle.
②. Remove the hub of steering knuckle.
Attentions
1.
In case of removing the drive shaft with a
shaft bracket, it may cause the deformation of
connecting shaft bracket, so the drive shaft
and connecting shaft shall be removed and
installed as a whole.
Before performing the following procedures,
be sure to first remove ABS wheel speed
sensor, otherwise it may the open circuit of
wires due to wrong pull or operation.
③. Remove it in the sequence shown in the table.
④. Install it in the reverse sequence of removal.
Lock nut
Refer to the keypoints for removal of M lock nut. Refer to the keypoints for installation of
M lock nut.
Ball joint of steering tie rod end socket
Refer to the keypoints for steering tie rod end socket ball joint.
Lower control arm ball joint
Left drive shaft
Refer to the keypoints for removal and installation of M drive shaft.
Drive shaft and connecting shaft
Refer to the keypoints for removal and installation of M drive shaft and transmission drive
axle.
Drive shaft
Refer to the keypoints for removal of M drive shaft.
Snap ring
Refer to the keypoints for installation of M snap ring.
List of tires and drive shafts 2B-4
shall not exceed the specified value in
installation technology requirements.
Keypoints for removal of drive shaft
1.
Remove the riveting bolt and nut.
2.
Wrap the cloth on the dustproof rubber sleeve
of ball joint.
3.
Pry the lower control arm out of steering
knuckle.
2.
After the installation, measure the outer
diameter of snap ring. If it exceeds the
specified value, additionally renew a snap
ring, and repeat Steps 1-2.
Technical requirements for snap ring outer
diameter: 26 mm {1. 02 in}
Snap ring
Opening
Outer diameter
Cloth
4.
Attach the spare nut to drive shaft to make the
nut flush with the end of drive shaft.
Keypoints for installation of drive shaft and
transmission drive axle
5.
Hit the nut lightly with a copper hammer to
loosen the drive shaft from front hub.
Note
6.
Take the drive shaft out of hub.
The sharp edges of connecting shaft may scratch
the oil seal, so it should be specially careful to
install the drive shaft into the transmission drive
axle.
1.
Insert the drive shaft into the hub.
2.
Apply ATF to the lip of oil seal.
3.
Push the drive shaft into the transmission
drive axle.
4.
After the installation, draw the outer ring on
one end of transmission drive axle forward,
and confirm that the drive shaft is locked by
the snap ring.
Note: the sharp edge of drive shaft will scratch the
oil seal, so it’s specially careful to remove the
drive shaft from the transmission drive axle.
7.
Insert a crowbar between outer ring and
transmission drive axle, and pry the left drive
shaft from transmission drive axle, as shown
in the figure below.
Disassembly and assembling of drive shaft
Keypoints for installation of snap ring
1.
While attaching a new snap ring to the
connecting shaft, make the opening of snap
ring up, and ensure the diameter of snap ring
1.
Disassemble it in the sequence shown in the
table.
2.
Assemble it in the reverse sequence of
disassembly.
List of tires and drive shafts 2B-5
1
Wheel side dustproof rubber sleeve clamp
Refer to the keypoints for disassembling M wheel side dustproof rubber sleeve clamp. Refer
to the keypoints for assembling M wheel side dustproof rubber sleeve clamp.
2
Transmission drive axle side dustproof rubber sleeve clamp
Refer to the keypoints for disassembling M transmission drive axle side dustproof rubber
sleeve clamp. Refer to the keypoints for assembling M transmission drive axle side dustproof
rubber sleeve clamp.
3
Outer ring
Refer to the keypoints for disassembling M outer ring. Refer to the keypoints for assembling
M outer ring
4
Snap ring
5
3-foot universal joint
Refer to the keypoints for disassembling M 3-foot universal joint. Refer to the keypoints for
assembling M 3-foot universal joint.
6
Dustproof rubber sleeve
Refer to the keypoints for disassembling M dustproof rubber sleeve. Refer to the keypoints for
assembling M dustproof rubber sleeve.
7
ABS sensor rotor
Refer to the keypoints for disassembling M ABS sensor rotor. Refer to the keypoints for
assembling M ABS sensor rotor.
8
Shaft and ball joint assembly
List of tires and drive shafts 2B-6
Keypoints for disassembling
dustproof rubber sleeve clamp
wheel
side
Note
Only when the dustproof rubber sleeve clamp is
replaced, it’s required to remove the dustproof
rubber sleeve clamp with clamp forceps and scrap
it, as shown in the figure below.
Note: make the mark with paint, and don’t punch
the mark.
1.
For the purpose of correct assembly, make the
mark on the shaft and 3-foot universal joint.
2.
Remove the stop ring with clip forceps.
3.
Remove 3-foot universal joint from the shaft.
Mark
Keypoints for disassembling dustproof rubber
sleeve
Keypoints for disassembling transmission drive
axle side dustproof rubber sleeve clamp
Remove big or small clamp with clamp forceps.
Note: unless it’s necessary to replace the dustproof
rubber sleeve ball joint and shaft assembly, don’t
remove the dustproof rubber sleeve on wheel side
under common conditions; remove the paper tape
after assembling the dustproof rubber sleeve.
1.
Wrap the spline of shaft with a tape.
2.
Remove the dustproof rubber sleeve.
Paper tape
Keypoints for disassembling outer ring
1.
Make a mark for correct assembling on the
outer ring and shaft.
2.
Remove the outer ring.
Keypoints for disassembling ABS sensor rotor
Note:remove the sensor rotor only if
necessary. Once the sensor rotor is removed,
it can’t be used any longer.
1.
Mark
Keypoints for disassembling 3-foot universal
joint
Hit down ABS sensor rotor from the drive
shaft lightly with a chisel.
Keypoints for assembling dustproof rubber
List of tires and drive shafts 2B-7
sleeve
Note: the dustproof rubber sleeves are different
from each other on wheel side and transmission
drive axle side; apply the specified grease supplied
in kits of dustproof rubber sleeve.
1.
1.
After wrapping the hoop by a turn, clamp it
with clip forceps;
2.
Lock the hoop with a locking clamp;
Apply the specified grease to the dustproof
rubber sleeve on wheel side.
Filling capacity: 90-110 g {3.13- 3.82oz}
2.
Since the spline of shaft has been wrapped
with a taper during the removal, the dustproof
rubber sleeve can be mounted at this time.
3.
Remove the tape.
Keypoints for assembling 3-foot universal joint
1.
nstall 3-foot universal joint with a crowbar
and hammer by aligning to the mark;
Keypoints for assembling the dustproof rubber
sleeve clamp on wheel side
1.
Turn SST adjusting bolt to adjust the
clearance A.
Clearance A:2.9 mm {0.11 in}
Adjusting screw
2.
Install the new stop ring with clip forceps.
Keypoints for assembling outer ring
Note: apply the specified grease supplied in kits of
dustproof rubber sleeves.
1.
Apply the specified grease to the outer ring
and transmission drive axle side dustproof
rubber sleeve;
2.
Filling capacity of grease:130-140g {4.59-4.95oz}
2.
Assemble the outer ring;
3.
Wrap the head of screwdriver with a cloth,
then lift up the small end of each dustproof
rubber sleeve carefully, and drain the air
remaining in dustproof rubber sleeve.
Lock the small dustproof rubber sleeve clamp
on wheel side with SST, and ensure the
clearance B conforms to the provisions for
technical requirements. If the clearance B
exceeds the specified value, reduce the
clearance A of SST, and re-lock the dustproof
rubber sleeve. If the clearance B is below the
specified value, replace the dustproof rubber
sleeve clamp, increase the clearance A of SST,
and lock the new dustproof rubber sleeve;
Clearance B: 2.4-2.8 mm
Keypoints for assembling the transmission drive
axle side dustproof rubber sleeve clamp
Note: the new hoop must be used every time. The
wrapping direction of hoop should be reverse to
forward rotation direction of drive shaft.
{0.095-0.110 in}
3.
Ensure the dustproof rubber sleeve clamp
shall not be outside the clip mounting area. If
List of tires and drive shafts 2B-8
any of above cases occurs, replace the hoop,
and repeat Steps 2 and 3;
4.
Fill in the dustproof rubber sleeve with the
grease supplied in repair kits;
5.
Turn SST adjusting bolt to adjust the
clearance A.
Clearance A: 3.2 mm {0.13 in};
6.
Lock the big dustproof rubber sleeve clamp
on wheel side with SST;
7.
Ensure the clearance B conforms to the
provisions for technical requirements;
If the clearance B exceeds the specified value,
reduce the clearance A of SST, and re-lock the
dustproof rubber sleeve. If the clearance B is
below the specified value, replace the dustproof
rubber sleeve clamp, increase the clearance A of
SST, and turn the edges of new dustproof rubber
sleeve up to clearance B: 2.4-2.8 mm {0.095-0.110
in};
8.
Ensure the dustproof rubber sleeve clamp is
not outside the hoop mounting area. If any of
above cases occurs, replace the hoop, and
repeat Steps 7 and 8.
Wheels and tires 2C-1
Chapter 12
Wheels and tires
Description and operation ......................................................................................................................2C-2
Tires and wheels................................................................................................................................ 2C-2
Tread ................................................................................................................................................. 2C-2
Buffer layer ....................................................................................................................................... 2C-2
Tire body ........................................................................................................................................... 2C-2
Tire bead ........................................................................................................................................... 2C-2
Tire tube ............................................................................................................................................ 2C-2
Sidewall of tire .................................................................................................................................. 2C-2
Tire .................................................................................................................................................... 2C-2
Tire hydroplaning.............................................................................................................................. 2C-2
Standing wave ................................................................................................................................... 2C-3
Tire rotation....................................................................................................................................... 2C-3
All season tire.................................................................................................................................... 2C-3
Tire label ........................................................................................................................................... 2C-3
Spare tire ........................................................................................................................................... 2C-3
Wheel ................................................................................................................................................ 2C-3
Tire pressure...................................................................................................................................... 2C-3
Tire rotation....................................................................................................................................... 2C-4
Wheel balance ................................................................................................................................... 2C-4
Diagnostic data and procedures.............................................................................................................2C-4
Tire wears.......................................................................................................................................... 2C-4
Repair instructions ............................................................................................................................ 2C-6
Instructions........................................................................................................................................ 2C-7
Wheels and tires 2C-2
Description and operation
Width
Tires and wheels
Tread
The portion contacting the road surface outside the
buffer layer and tire body. It’s made of high wearresistant rubber. Its operation is determined by its
surface details.
Inner
diameter
Outer
diameter
Buffer layer
The fabric layer between the tread and tire body is
used to prevent the damages of tires caused by
road impacts and vibration.
Width
Tire body
Height
This main portion is a tire-like structure consisting
of high-strength synthetic fiber cord fabric. Since it
must maintain the tire pressure and bear all the
loads and vibrations of tires, so it must have high
fatigue-resistant properties.
Tire bead
The steel wire coil on ends of tire body, which is
covered with rubber layers and wrapped with
nylon threads. It’s used to fix the tire on the rim.
Tire tube
185
5
84H
(Height/width)×100
R
15
Sidewall of tire
It’s used to protect the tire body, flexing resistant
and improve the driving comfort.
Flatness rate 60%
60
185/60R1
The most tires applied in modern vehicles are
tubeless tires.
Width (mm)
Radial tire
Rim diameter
(Inner diameter of tire, feet)
84
Max. load index
H
Max. speed rating
Tire
Tire hydroplaning
Structure of tubeless tire
When the vehicle is driving on the road surface
with water at high speed, it will make the tires
unable to drive like rolling on the good road
surface, thus the tires may float on it. This is called
as tire hydroplaning.It will cause the failure of
brake, low friction force and steering failure, so
it’s very dangerous.
Buffer layer
Sidewall
Tread
Tire body
Tire bead
Inflating
valve
High-speed driving
Low-speed driving
Wheels and tires 2C-3
Standing wave
All season tire
During the rotation of tires, the tread will produce
the repeated deformations and restoring torques.
However, the new deformation has been produced
and the previous deformation still exists at higher
speed, so a vibration wave will be produced on
local part of tread. The lower the tire pressure is,
the more serious its vibration wave is, especially at
high speed.
Now, most of vehicles are equipped with all season
PCR tires as standard configurations. These tires
can be used as snow tires. During the use in the
snow, their average ratio is 37% higher than
friction coefficient of non-all season tires. In other
aspects, e.g.their wet water friction coefficient,
rolling resistance, tread service life and air
resistance are all improved, because the design of
tread patterns and tread compound are also
improved. These tires have “M+S” engraved
behind their tire side marked size codes. The suffix
“MS” is also engraved behind the instructions for
tire side TPC numbers.
Not all the steering wheel tires are all season tires.
These tires have no “MS” marks behind the tire
sizes or behind the instructions for TPC numbers.
Tire label
Tire rotation
As indicated in the tire performance criteria (TPC),
the numbers have been engraved in the tire side
mold near to tire size. It indicates that these
numbers include the traction force index, strength,
size and rolling resistance conforming to the
criteria. Generally speaking, each size of tire shall
have different TPC numbers.
Note: Don’t use different types of tires on the
same vehicle, e.g.radial tire and bias tire, except in
emergency cases, because the vehicle will be
seriously influenced, and it may cause the control
failure of vehicle.
Replace the original tires with the tires of the same
size, load and structure. The use of other sizes or
structures of tires will seriously influence the ride
comfort, steering properties, speedometer /
mileometer values, vehicle ground clearance, and
clearance from tire to vehicle body or chassis. But
it’s not applicable for spare tires.
It’s recommended to replace a pair of tires on the
same shaft synchronously during the renewal of
tires.
If it’s required to replace a tire, find a nearest tread
to compensate the braking coefficients.
Different producers design different tread patterns,
but the same TPC number may be used on the
same vehicle.
The tire labels shall be permanently affixed behind
the side door of driver’s seat, and the tires shall be
inflated as per the above tire pressure. The
maximum vehicle load, tire specifications
(including the spare tire) and inflating pressure
((including the spare tire) are described on the tire
labels.
Spare tire
This vehicle is equipped with full-size wheels and
spare tires on it.
Wheel
If any of the following cases occur to the wheels,
they must be replaced: bends, indentions, flanging
or deflected jumps, air leakage of weld joints,
enlargement of bolt holes, or fixing failure or
serious rusting of bolts. The jumps of wheel
transition will cause the vibration of vehicle. Any
replaced wheel must have the same load, diameter,
rim width, offset distance and mounting size as
those of original wheel. The inconformity of wheel
size or type will influence the service life of wheel
and bearing, cooling of brake, readings of
speedometer/kilometer, vehicle ground clearance,
and clearance from tire to vehicle body and chassis.
Tire pressure
The recommended air pressure of any vehicle tire
shall be carefully calculated, which will give your
driving/ride comfort, good steering ability, extend
the service life of tire, and ensure its loading
capacity.
Check the tire every 5,000km. The tire pressure
must be checked every month or before driving it
for long distance. The tire must be checked at low
Wheels and tires 2C-4
temperature, i.e. when the vehicle drives for about
3 minutes or at less than 1. 6km/hour. Inflate the
tire as per the air pressure indicated in the tire label
on driver’s seat side door. The inflation pressure of
tire has been given in “Instructions for Tire
Specifications and Inflation Pressure” of this
section.
Minimum pattern depth
1.6mm(0.06 inch)
The inflating valve must have a nut cap on it,
which is used to prevent the dust and water from
entering into it.
The air pressure above the recommended pressure
will lead to:
●
Harder ride and driving
● Explosion or damages of tire
●
Rapid wears of tread in the middle of tire
The air pressure below the recommended pressure
will lead to:
● Large noises while turning
●
Difficult steering
●
Rapid or uneven wears of both sides of tire
●
Scratches or cutting of tire edges
●
Fracture of tire cord
At higher tire temperature, its different tire
pressure on the same shaft will lead to:
●
Uneven braking force
●
Heavy steering
●
Reduction of handling stability
●
Sudden steering during the acceleration
●
Direction of torque control
Wheel balance
It’s a simple process to check the wheel balance. If
the wheel jumps at high speed, it shall be first
checked by you. During the replacement of wheels
and tires, their balances must be checked.
While checking the wheel balance, be sure to
follow the rules below:
①
The number of balance blocks shall not
exceed two on inner or outer side of one
wheel;
②
The total weight of one wheel balance block
shall not exceed 100g (3.5 ounce);
Diagnostic data and procedures
Tire wears
①
Check the depth of tire pattern.
②
If the depth of its pattern is below the given
value, please replace the tire.
Tire rotation
Front and rear tires have different functions and
will lead to uneven wears, which is determined by
road surfaces for driving and different driving
habits,etc. The wear rate of front wheel tire is
below that of rear wheel tire.
In order to avoid uneven wears of tire and extend
its service life, rotate the tire every 10,000km.
After rotating the tire, adjust its air pressure, and
ensure that the torque of hub nut meets the
specified requirements.
It can be seen from the specifications that the tire
must be replaced when the depth of tire pattern is
reduced (below 1. 6mm (0. 06 inch)).
Wheels and tires 2C-5
Irregular or excessive wears of tire
Fault
Possible causes
Corrective measures
● Overlow tire pressure
● Adjust the tire pressure.
● Improper tire rotation
● Rotate the tire.
● Overhigh tire pressure
● Adjust the tire pressure.
● Improper tire rotation
● Rotate the tire.
● Improper toe-in
● Adjust the toe-in.
● Reverse toe-in
● Adjust the toe-in.
● Improper kingpin caster angle
or
improper
front-wheel
camber
● Check the steering knuckle,
control connecting rod, drive
shaft and suspension. Replace
if necessary.
● Suspension failure
● Improper wheel balance
● Improper tire rotation
● Adjust the balance of wheel.
● Rotate the tire.
Wheels and tires 2C-6
Repair instructions
(I)
Vehicle repair
hitting the wheel or tire, will also cause the
damages, which can’t be recovered. It’s allowed to
hit the sides of wheel slightly with a hand or
rubber hammer.
④
Remove the wheel.
If it’s difficult to remove the wheel from the
vehicle, it may be caused by the existence of
sundries or excessive close fit among the wheel
middle holes, nuts and hubs. At this time, the
wheel can be removed from the vehicle by
adopting the following methods:
A.
Re-tighten any influenced hub nut, and then
turn the hub nut two circles in its loosening
direction.
B.
Lower the vehicle, try to shake the vehicle,
and adopt the weight of one or several
persons to loosen the wheel.
C.
Lift up the vehicle again, and then remove the
wheel.
Note: don’t apply the lubricating oil to vertical
surface of wheel and hub (or brake disc), because
the existence of lubricating oil in these positions
will lead to the wheel loosening when the vehicle
is driven, control failure of vehicle and even
serious accidents. The lubricating oil is not good
for removal of tightened wheel. If the lubricating
oil is required, don’t apply too much oil, and only
to the centerhole area of wheel.
II.
Sequence of installation
Note: before installing the wheel, please remove
the sundries from the mounting faces of wheel,
brake drum and hub with a hairbrush. If the surface
contact is poor during the installation, it will
loosen the hub nut. While the vehicle is driving,
there may be a risk of disengaging the wheel from
the vehicle. The hub nut must be tightened as per
the specified torque, but its tightening force shall
not be excessive, thus the bends of wheel, brake
drum or hub can be avoided.
Wheel
I.
Sequence of removal
①
Remove the steel wheel outer trim cover;
② Remove the hub nut;
③
Lift the wheel stably.
Note: don’t loosen the tightened wheel by heating
it. It will shorten the service life of wheel, hub nut
and wheel bearing. Excessive force application, e.g.
①
Install the wheel.
②
Install the hub nuts in diagonal order. Don’t
tighten the hub nut.
③
Lower the vehicle.
④
Tighten it.
Tighten the hub nuts up to the torque of 100 to 120
N.m (73.3 to 88.3 lb-ft).
⑤
Wheel balance
Measure the balance of wheel with an automatic
balancing machine. The balancing machine is
convenient in operation, its static and dynamic
Wheels and tires 2C-7
balance can be also measured. Unlike the balance
of vehicle, don’t calibrate the unbalance of vehicle,
brake drum or hub. This defect can be resolved by
precision. During the balancing work, make the
taper part through the wheel center hole to fix the
wheel, and don’t do so through the mounting hole
of hub nut.
⑥ Calibrate the unbalanced tire.
Provide two methods to calibrate the unbalanced
tire.
One method is to fix the tire through this automatic
device, and then hit small yellow rubber blocks on
both sides of tire tread. Such calibration method is
usually permanent.
If it’s well handled, it won’t influence its
appearance or tire service life.
It’s not recommended to calibrate any tire with a
blade-shape machine, because it can reduce the
service life of tire tread, and the tire can’t be
permanently calibrated.
or tire must be known before doing so, because
this method can ensure the balance of its assembly.
⑦ Installation of tire and wheel
The tire and wheel shall be installed in the
assembling workshop. During the installation,
install them by aligning the radial hard point or
heavy balancing point of tire to the radial dot or
light balancing point of wheel.
The heavy balancing point of tire is marked with a
red dot during the start of its production, or marked
on the tire side with a label.
The light balancing point of wheel is located at the
inflating valve.
Before installing the tire and wheel, scribe a line
on the tire and inflating valve to ensure that they
can be installed in the same position during the reinstallation.
The quality of spare tire and original tire shall be
the same, and their heavy and light points shall be
marked with the same method.
The other method is to remove the tire, and then
turn it by 180‫ ﹾ‬on the rim. The unbalance of wheel
Instructions
Instructions for tire size and air pressure
Inflation pressure
Tire
Wheel
185/60 R15
195/55 R15
Front
Rear
kPa
psi
kPa
psi
15×5. 5J (steel)
220
32
220
32
15×6J (aluminum)
220
32
220
32
Instru`ctions for converting the inflation pressure
kPa
psi
kPa
psi
kPa
psi
140
20
186
27
234
34
145
21
193
28
241
35
152
22
200
29
248
36
159
23
207
30
276
40
166
24
214
31
310
45
172
25
220
32
345
50
179
26
228
33
379
55
Instructions for tightening torque
Type
N.m
Ib.Ft
Ib.In
Hub nut(aluminum alloy
wheel)
100 to 120
66 to 81
－
Hub nut(steel wheel)
100 to 120
66 to 81
－
Suspension system 2D-2
Suspension system 2D-1
Chapter 13 Suspension system
General procedures .................................................................................................................................2D-2
Attentions for suspension system......................................................................................................2D-2
Front suspension......................................................................................................................................2D-3
Check of front shock absorber ..........................................................................................................2D-2
Warning for scrapping the front shock absorber ...............................................................................2D-2
Removal/installation of front suspension lower swing arm assembly ..............................................2D-3
Removal/installation of front transverse stabilizer bar......................................................................2D-4
Rear suspension.......................................................................................................................................2D-5
Removal/installation of rear shock absorber and spring ...................................................................2D-5
Notes for mounting rear spiral spring................................................................................................2D-6
Removal/installation of torsion beam integral axle...........................................................................2D-6
Suspension system 2D-2
Location of wheel
General procedures
Attentions for suspension system
Initial check of wheel location
1.
Check the inflation of tire, and adjust its
pressure to the recommended pressure as per
the demands.
2.
Check the front wheel bearing clearance, and
apply the necessary calibrations to it as per
the demands (refer to the check of M wheel
bearing clearance).
3.
Check the radial runout of wheel and tire
(refer to TD suspension).
4.
Check the ball joint and steering linkage for
excessive loosening.
5.
Shake the vehicle body to check the operation
of shock absorber.
Removal/installation of wheel and tire
1.
Its tightening torque during the installation of
wheel:100-120N.m {10. 0-12. 0kgf.m,77. 388. 3in.lbf}
Removal/installation of suspension tie rod
1.
Each part of suspension with rubber bush can
be tightened only after the vehicle is laid
down and at empty load.
Empty load: the fuel tank is full, the levels of
cooling oil and lubricating oil in engine reach the
specified liquid level, the spare tire jack and tool
are placed in specified positions.
Cutoff/connection of brake pipe
Note: the brake oil will damage the paint surface.
If the brake oil contacts with the paint surface,
remove it immediately.
1.
2.
Tighten the brake pipe taper nut with SST
special service tool 490 259 770B, and
confirm the adjustment of brake pipe taper nut
tightening torque to ensure the combined use
of torque wrench and SST special service tool.
If any brake pipe is disconnected in this
process, add in the brake oil, remove the
residual air out of brake system, and check it
for leakage after terminating the operation.
Removal/installation of power steering part
1.
Note: the vehicle must be placed on horizontal
road surface at empty load.
Empty load: the fuel tank is full, the levels of
engine cooling oil and lubricating oil reach the
specified liquid level, the spare tire jack and tool
are placed in specified positions.
6.
Measure the vertical height from wheel center
to wheel fender edge, and the difference
between the values measured on left and right
sides can’t exceed 10mm {0.39 in}.
Measured point
A-A section
If any power steering oil line is disconnected
in this process, add in DEXRON-III or ATFIII oil, remove the residual air out of oil line,
and check it for leakage after terminating the
operation.
Location of front wheel Technical parameters (empty load)*1
Item
Total toe-in
mm {in}
°
Maximum value of steering Inner side wheel
angle
Outer side wheel
kingpin caster angle(reference value) *2
front-wheel camber
Kingpin inclination angle (reference value)*2
Parameters
0±2
0°00’±0°12’
37. 79°
33. 36°
2°35'±30'
-0°30'±30'
13°20'±30'
1. The levels of engine cooling oil and lubricating oil reach the specified liquid level, and the spare tire jack
and tool are placed in specified positions.
2. The difference between the values measured on left and right sides can’t exceed 1º30’.
Suspension system 2D-3
1.
Loosen the end lock nuts of steering linkage.
Note: turn each of both steering linkages by a
complete circle, and change the toe-in by about
6mm {0.24 in} 0º36’.
2.
Remove the steering gear boot clamp.
3.
Adjustment of maximum steering angle
Tighten the lock nut of steering linkage up to
the specified tightening torque: 66-86N.m
3. Make the length of steering linkage equal to L.
{6.0-8.6kgf.m, 48.7-63.4in.lbf}
Difference between left and right
Location of rear wheel
values is below 3mm(0. 12in)
Technical parameters (empty load)
Indications of fuel
meter
Total toeout
Empty--full
mm
3±3
Rear wheel camber
angle (reference value)
Maximum difference between left/right values of
3mm {0.12 in}
4.
5.
Adjust the steering linkage evenly to ensure
its corresponding maximum steering angle.
Tighten the end lock nut of steering linkage.
Tightening
torque:
66-86N.m
{6.08.6kgf.m,48.7-63. 4in.lbf}
6.
Ensure that the gland cover is not twisted, and
install the boot clamp.
7.
Adjust the toe-in after adjusting the steering
angle.
Adjustment of total toe-in
1.
Locate the steering wheel in middle position,
and ensure that the wheel/tire is right ahead.
2.
Loosen left and right steering linkage lock
nuts, keep the rotations of both side linkages
equal to each other, both side steering
linkages are right hand threads, so right
steering linkage shall be turned in front of
vehicle, and left steering linkage shall be
turned back to increase the toe-in.
-1°00’±45’
Front suspension
Removal/installation
absorber and spring
of
front
shock
Note
In case of not removing ABS anti-lock brake
system wheel speed sensor first, carry out the
following operation procedures. If the sensor is
inadvertently pulled, it may cause the broken
circuit of wire. Before carrying out the following
operation procedures, remove ABS wheel speed
sensor from axle side, and fix it in appropriate
position to prevent the sensor from inadvertent
pulling during the repair of vehicle.
1.
Remove it in the sequence shown in the table;
2.
Install it in the reverse sequence of removal;
3.
Check the location of front wheel. In case of
not conforming to the standard provisions,
adjust the location of front wheel (refer to the
location of R front wheel).
Suspension system 2D-4
1
Bolt
hose
and
brake
2
Fixing bolt and nut
of shock absorber
andsteering
knuckle
8
Upper
mount
3
Fixing nut of shock
absorber
and
vehicle body
9
With a stop
block dust cover
10
Front
spring
spiral
11
Lower
mount
rubber
12
Front
shock
absorber
assembly
7
Upper bracket
of spiral spring
and death. Ensure that the shock absorber shall be
installed inside SST special service tool before
removing the piston rod nut.
1.
Protect the spiral spring with a cloth, and then
place SST special service tool.
2.
Compress the spiral spring and remove the
piston rod nut with SST special service tool.
rubber
Piston rod nut
4
5
6
Refer
to
the
keypoints
for
removal of R-4
piston rod nut.
Upper support of
damping column
Damping
bearing
column
Keypoints for removal of piston rod nut
Warning:
It’s dangerous to remove the piston rod nut, the
shock absorber and spring may pop up due to huge
pressure, thus it will lead to serious personal injury
In case of applying the engine support
Suspension system 2D-2
Keypoints for installing the stop block
Apply the grease to the contact surface of stop
block and dust cover.
Keypoints for installing the dust cover
Apply the grease to the contact surface between
the dust cover and upper spring retainer.
Keypoints for installing the spiral spring
1.
2.
First install the upper spring rubber retainer
and upper spring retainer on the shock
absorber to make the lower end of helical
spring placed on lower spring retainer.
As shown in the figure, make the marks on
upper spring rubber retainer and upper spring
retainer on spiral spring for the purpose of
correct installation.
Tightening torque of piston rod nut:80-90N.m{8-9
kgf.m, 59-66. 4in.lbf}
Keypoints for installing front shock absorber
and spring
The upper support of shock absorber has wronginstallation-proofing functions, which ensure no
wrong installation during the installation.
Check of front shock absorber
Upper spring
retainer
3.
Exterior
of vehicle
Mark
Align the marks on upper spring rubber
retainer and upper spring retainer of spiral
spring, protect the spiral spring and upper
retainer spring with cloth, and then set SST
special service tool.
Compress the spiral spring with SST special
service tool.
5.
Install the lower spring rubber retainer on
lower spring retainer.
7.
8.
Remove front shock absorber from the
vehicle.
2.
Check the shock absorber for damages or oil
leakage.
3.
Check the rubber bush for aging and wears.
4.
Compress and stretch the shock absorber
piston at least three times, confirm the
unchanged operating force and no abnormal
noises. If it can’t conform to the standards,
replace the shock absorber.
Dent
4.
6.
1.
Install the shock absorber to make the lower
end of spiral spring placed on lower spring
retainer.
Ensure that the marks of shock absorber and
upper spring retainer are aligned to each other.
(1) Compress the shock absorber piston, and then
release it.
(2) Confirm that the piston stretches and returns
at normal speed.
Warning for scrapping the front shock
absorber

Wear the safety goggles in case of each
drilling of shock absorber, because the highpressure gas in the shock absorber may inject
the metal shavings to the eyes and faces while
drilling.
1.
Clamp the shock absorber down on the plane
by making the piston down.
2.
Drill a hole φ2-3 mm {0.08-0.12 in} in the
position 20-30mm {0.8-1.2 in} away from the
pipe bottom to make the gas leaked out.
As shown in the figure, install the bearing
fixing rubber seat and piston rod nut, and then
remove SST special service tool.
Suspension system 2D-3
Keypoints for removing the lower swing arm
front bush
Press it down with SST special service tool, and
remove the lower swing arm front bush.
Hydraulic machine
pressed in by force
is
Special tools
3.
Make the hole down.
4.
Collect the oil by moving up and down the
piston rod several times and cutting the pipe
ends.
5.
Handle the waste oil as per the waste material
processing regulations.
Note: the gas applied in the shock absorber is
nitrogen, and the oil applied in the shock absorber
is mineral oil.
Front bush
Special tools
Keypoints for removing the lower swing arm
rear bush
1.
As shown in the figure, align to rear small
bump of lower swing arm bush, and make the
mark on lower swing arm for the purpose of
correct installation.
Removal/installation of front suspension
lower swing arm assembly
1.
2.
Remove it in the sequence shown in the
table.
Small bump
Install it in the reverse sequence of
removal.
Mark
2.
1
Self-lock nut
2
Self-lock nut
3
Hexagon flange bolt
4
Hexagon flange bolt
5
Hexagon flange bolt
6
Front suspension lower swing arm assembly
7
Swing arm front bush
8
Swing arm rear bush
Press it down with SST special service tool to
remove the bush of lower swing arm.
Press in
Keypoints for removing the dust cover
Remove the dust cover with a chisel, and don’t
damage the ball joint and arm lever.
Keypoints for installing lower swing arm rear
bush
Suspension system 2D-4
1.
As shown in the figure, align the mark of
lower swing arm to small bump behind lower
swing arm bush.
4.
Wipe off the excessive grease.
Small bump
Mark
2.
Install the lower swing arm on SST special
service tool.
3.
Press new bush of lower swing arm with SST
special service tool.
Check of front lower swing arm
1.
Remove lower swing arm from the vehicle.
2.
Check it for damages, cracks and bends.
3.
Check the rotation torque of ball joint.
(1) Turn the ball joint five times.
(2) Connect SST special service tool to ball head
bolt, and measure its rotation torque with a
tension meter. If unqualified, replace the
lower swing arm.
Press in
Pre-load of ball joint: 1.0 -4.9N.m {0.1-0.5kgf.cm,
0.74-3.6in.lbf}
Reading of tension meter: 10-49N {1-5kgf, 0.2251.1lbf}
Keypoints for installing the lower swing front
bush
Press a new bush into swing arm body with SST
special service tool.
Hydraulic machine is
pressed in by force
Removal/installation of front transverse
stabilizer bar
Special tools
1.
Remove the front suspension crossbeam
assembly (refer to the removal/installation of
R-9 front suspension crossbeam assembly).
Front bush
2.
Remove front control connecting rod
assembly lower fixing nut or lower bush
assembly ①.
3.
Remove front control connecting rod
assembly and stabilizer bar connecting nut ②.
4.
Remove front transverse stabilizer bar fixing
plate nut, front transverse stabilizer bar fixing
plate, and stabilizer bar rubber sleeve ③.
5.
Install it in the reverse sequence of removal.
Special tools
Keypoints for installing the dust cover
1.
Wipe off the grease from the ball head bolt.
2.
Fill the grease into the new dust cover.
3.
Press the dust cover on the ball joint with SST
special service tool.
Suspension system 2D-5
Keypoints for installing
stabilizer bar fixing plate
front
Install the assembly in the reverse sequence of
removal.
8.
Check the location of front wheel, and adjust
its location if necessary.
transverse
1.
Apply the rubber grease to inner surface of
stabilizer bar rubber sleeve.
2.
In case of installing the rubber sleeve, make
the cut of rubber sleeve towards the rear of
vehicle, and align its boss to the notch of front
beam.
3.
7.
Keypoints for removing the front suspension
crossbeam assembly
1.
Front transverse stabilizer bar fixing plate.
Stabilizer bar rubber
sleeve
Front
Notch
Support the front suspension crossbeam
assembly with a jack, and remove the bolts
connected to vehicle body.
Bolt torque: 141 to 223N.m {14.1 to 22.3 kgf.m,
104 to 165in.lbf }
2.
Remove the front suspension crossbeam
assembly.
Rear suspension
Boss
Stabilizer bar fixing plate
Removal/installation of front suspension
crossbeam assembly
1.
Remove the rubber lug of exhaust pipe (refer
to removal/installation of F exhaust system).
2.
Remove the engine mounting arm (refer to the
keypoints for removing B engine support
beam).
3.
Remove the steering gear and tie rod(refer to
removal/installation of N steering gear and tie
rod).
4.
Remove the front suspension lower swing
arm assembly(refer to removal/installation of
R-6 front suspension lower swing arm
assembly).
5.
Remove front transverse stabilizer bar(Refer
to removal/installation of R-8 front transverse
stabilizer bar).
6.
Remove the fixing bolt ①of front suspension
crossbeam assembly.
Removal/installation
absorber and spring
of
rear
shock
Note:
In case of not removing ABS anti-lock brake
system wheel speed sensor first, carry out the
following operation procedures. If the sensor is
inadvertently pulled, it may cause the broken
circuit of wire. Before carrying out the following
operation procedures, remove ABS wheel speed
sensor from axle side, and fix it in appropriate
position to prevent the sensor from inadvertent
pulling during the repair of vehicle. During the use
of jack, be sure to avoid the damages of brake pipe
and brake hose.
1.
Remove them in the sequence shown in the
table.
2.
Install them in the reverse sequence of
removal.
Suspension system 2D-6
mount
3
Rear spiral spring lower rubber mount
4
Rear spiral spring
5
Rear spiral spring upper rubber mount
Notes for mounting rear spiral spring
Install the spiral spring with its open end in front
of vehicle, and ensure that the opening of rear
spiral spring lower rubber mount is always
clamped.
Warning
It’s very dangerous to install the spiral spring,
because the spiral spring may fly off and lead to
serious injury or death.
1
Hexagon flange bolt
2
Self-lock nut
Removal/installation
integral axle
3
Upper mounting cover of rear shock
absorber
1.
4
Upper bush
Lift the vehicle to its appropriate position, and
remove the tire(refer to the installation
sequence of 2E-8 wheel).
5
Rear shock absorber assembly
2.
Remove the rear brake drum assembly (refer
to Section 2E Wheel and Tire).
Check of rear shock absorber
3.
Check rear shock absorber by adopting the same
method as that of front shock absorber (refer to the
check of R-6 front shock absorber).
Jack up rear torsion beam assembly with a
screw block.
4.
Remove rear shock absorber assembly (refer
to removal/installation of R-10 rear shock
absorber and spring).
Handle rear shock absorber by adopting the same
method as that of front shock absorber (refer to the
scrapping of R-6 front shock absorber).
5.
Remove rear spiral spring (refer to
removal/installation of R-11 rear spiral
spring).
Removal/installation of rear spiral spring
6.
Remove it in the sequence shown in the table.
1.
Remove rear shock absorber assembly.
7.
Install it in the reverse sequence of removal.
2.
Remove it in the sequence shown in the table.
3.
Install it in the reverse sequence of removal.
Scrapping of rear shock absorber
1
Hexagon flange bolt
2
Spiral spring and upper/lower rubber
of
torsion beam
1
Hexagon flange bolt
2
Rear torsion beam assembly
Steering system 2F-1
Chapter 14
Steering system
General procedures ................................................................................................................................. 2E-2
Attentions for steering system........................................................................................................... 2E-2
Removal/installation of power steering assembly............................................................................. 2E-2
Disconnection and connection of joint.............................................................................................. 2E-2
Engine speed sensing power steering..................................................................................................... 2E-2
Exhaustion of air ............................................................................................................................... 2E-2
Check of power steering oil .............................................................................................................. 2E-2
Check of steering wheel and steering column................................................................................... 2E-4
Removal and installation of steering wheel and steering column ....................................................... 2E-5
Removal and installation of steering gear and connecting rod.......................................................... 2E-9
Disassembly of steering gear and connecting rod ........................................................................... 2E-11
Check of steering gear and connecting rod ..................................................................................... 2E-14
Assembling of steering gear and connecting rod ............................................................................ 2E-16
Removal and installation of power steering pump .......................................................................... 2E-20
Disassembly and assembly of power steering pump ....................................................................... 2E-21
Steering system 2F-2
2.
Jack up the front end of vehicle with a jack,
and support it with a safety support.
3.
Turn the steering wheel to left or right
furthest several times at the shutdown state of
engine.
4.
Check the level of power steering oil again. If
its level is reduced, refill the power steering
oil.
After removing the wheel, its tightening torque
during the reinstallation: 110N.m(100 to 120 N.m).
5.
Repeat Steps 3-4 until the liquid level
stabilizes at the specified value.
Removal/installation of power steering
assembly
6.
Lay down the vehicle.
If the power steering oil pipe is broken during the
operation, add in some ATF-III or DEXRON-
7.
Start the engine, and keep it idling.
8.
Turn the steering wheel to left or right
furthest several times.
9.
Confirm that the power steering oil shall have
no bubbles and its level shall not be reduced
any longer.

If its level has been reduced, add in the power
steering oil as per the demands, and repeat
Steps 8 and 9.
General procedures
Attentions for steering system
For removal/installation of wheel and tire
The installation steps of wheel and tire are not
described in this chapter.
III power steering oil after completing the
operation. Bleed the air out of power steering
pipe, and check it for leakage.
Disconnection and connection of joint
Before any work to contact the plug by hands,
disconnect the negative cable of battery. The cable
can be reconnected only after finishing the work.
Engine
steering
speed
sensing
power
Exhaustion of air
1.
Check the level of power steering oil(refer to
the check of power steering oil, and check of
liquid level).
Check of power steering oil
Check of oil level
Check the level of power steering oil.
If necessary, add in the power steering oil up to
the specified level. The model of such power
steering oil is ATF-III or DEXRON-III.
Steering system 2F-3
Leakage check of power steering oil
Note:
●
In case of keeping the steering wheel in the
extreme steering position for over 5s, the
temperature of power steering oil will be
increased to an extreme value, and produce
adverse influences on the power steering pump.
1.
Start the engine, and idle it.
2.
Turn the steering wheel to left or right furthest
several times to make the oil pressure produced
in every position.
Note:
●
The parts shown with the arrows of figure may
be leaked.
3.
Check them for leakage.
1.
Install the special tool as shown in the figure.
2.
Disconnect the high-pressure pipe from the oil
pump, and connect to its special tool.
Tightening torque:40-50N·m{4.0-5.0kgf.m}
3.
Bleed the air out of the system.
4.
Fully open the valve of pressure gauge.
5.
Start the engine, and turn the steering wheel to
left or right furthest to make the temperature of
power steering oil up to 50-60°C{122-140°F}.
6.
Fully close the valve of pressure gauge.
Check of power steering hydraulic force
Note:
If the valve is closed for over 5s, the temperature of
power steering oil will be increased to an extreme
value, and produce adverse influences on the power
steering pump.
Thermometer
7.
Increase the engine speed up to 1000-1500rpm,
and measure the pressure of power steering oil.

If the hydraulic pressure is not within the
specified range, it’s required to repair or
replace the power steering pump assembly.
Pressure gauge
Valve fully closed
Valve iron
Hydraulic pressure of power steering oil pump:
5.7-6.4Mpa{58.0-65.0kgf/cm2,826-928psi}
Note:
●
`
In case of keeping the steering wheel in the
extreme steering position for over 5s, the
temperature of power steering oil will be
Steering system 2F-4
increased to an extreme value, and produce
adverse influences on the power steering pump.
Thermometer
Pressure gauge
Valve fully
closed
8.
Fully open the valve of pressure gauge, and
increase the engine speed up to 1,0001,500rpm.
9.
Turn the steering wheel to left or right furthest,
and then measure the hydraulic pressure
produced in the gear chamber.

If the pressure is not within the specified range,
it’s required to repair or replace the steering
gear assembly.
Hydraulic pressure
chamber):
in
gear
chamber
(pump
5.7-6.4Mpa{58.0-65.0kgf/cm2,826-928psi}
10. Remove the special tool.
11. Install and tighten the high-pressure pipe, and
tighten it up to the specified torque.
Tightening torque:
40-50N.m{4, 0-5. 0kgf.m}
12. Bleed the air out of system.
Check of steering wheel and steering column
Check of steering wheel clearance
Stop the wheel directly in front, turn the steering wheel lightly to left or right, and confirm whether its
oscillation amplitude is within the specified range.
●
If the clearance is not within the specified range, it may be caused by wears of steering knuckle or
excessive clearance of steering gear, and apply the necessary corrections to it. Clearance: 0-30mm{0-1.
18in}.
Check of steering wheel loosening
Shake the steering wheel in the shown direction,
check the steering column bearing sleeve, steering
shaft hinge for oscillation, steering wheel for
loosening or steering column for loosening, etc.
Steering system 2F-5
to the following items:
Check of steering wheel steering force
1.
Check the following items.
－ Existence of air in the system
•
Tire size and tire pressure.
－ Hose or joint for leakage
•
Level of power steering oil.
•
Slack of drive belt.
－ The performances of power steering pump and
gear are perfect.
2.
Stop the wheel on firm or level road surface,
and make the wheel directly in front.
3.
Start the engine, and increase the temperature
of power steering oil up to 50-60°C{122140°F}.
4.
Remove the safety airbag module.
Warning:
Steering force: 7.8N·m{78kgf }.cm.
Note:
●
In order to judge the conformity of results,
check the steering operation of another
vehicle with the same model with the same
method under the same conditions, and
compare the test results.
●
The rotation torque of steering wheel varies
under the different conditions, as said below:
For removal/installation of safety airbag
module after the check, refer to
removal/installation of T safety airbag module
on driver’s side.
－ Road conditions, e.g. dry or wet road surface,
asphalt or cement road surface.
5.
Measure the steering force F with a torque
wrench.
－ Tire conditions, e.g. tire patterns, wears, tire
pressure, etc.
●
If not within the specified range, pay attention
●
Removal and installation of steering wheel and steering column
to the repair warning for safety airbag system.)
Warning:
●
Incorrect handling of safety airbag module
will make the safety airbag suddenly opened,
and it may cause the personal injury, so it’s
required to handle the safety airbag. Please
first read “Warning for Safety Airbag” (refer
1.
Remove them in the sequence shown in the
table.
2.
Install them in the reverse sequence of
removal.
Steering system 2F-7
1
Safety airbag: refer to removal/installation of safety airbag system,T dirver’s safety
airbag;
2
Lock nut
3
Steering wheel: refer to its removal instructions; refer to its installation instructions.
4
Steering column cover
5
Clock spring
6
Combination switch
7
Lower cover plate
8
Steering column: refer to its installation instructions.
9
Steering column lock sleeve
10
Steering column mount
11
Removed assembly of steering column: refer to its removal instructions.
Keypoints for removing the steering wheel
Note:
●
Don’t hit the steering shaft with a hammer
while removing the steering wheel, thus it will
cause the collapse of steering column.
1.
Make the wheel directly in front, and stop the
vehicle.
2.
Remove the steering wheel with an appropriate
puller.
Keypoints for removal of steering lock bolt
and support
1.
Make a groove in the lock bolt with a hammer
and chisel.
2.
Remove the bolt with a straight screwdriver.
3.
Disassemble the steering lock assembly.
Keypoints for removing
column external assembly
the
steering
Note:

During the replacement of its
assembly, its coil must be replaced.
1.
Turn the ignition key to “ACC” position.
2.
Press down the lock button, and pull out the
steering column external assembly.
external
Steering system 2F-8
Keypoints for installing the steering lock
bolt and support
1.
Install the steering lock assembly on the
steering shaft.
2.
Confirm the correct locking operation.
3.
Install the steering lock bolt.
4.
Tighten the bolt until its head falls off.
Keypoints for installing the steering shaft
Note:
●
Don’t shake the steering shaft in axial
direction.
1.
Tighten the bolt A.
2.
After tightening the bolt B, tighten the bolt C.
Keypoints for installing the steering wheel
1.
Adjust the sensing spring (refer to the
adjustment of safety airbag system sensing
spring).
2.
Make the wheel directly in front, and install the
steering wheel.
Check of steering shaft
1.
Check the following items, and replace the
steering shaft assembly if necessary:
－ Steering column bearing for damages.
－ Length of steering shaft.
Length: 813. 0-817. 0 mm{32. 0-32. 2in}
2.
Inclination operation
●
Confirm that the adjusting lever can move
stably from its unlocked position to locked
position.
●
Confirm that the steering shaft isn’t loosened
when the adjusting lever is locked.
Lock
Adjusting lever
Unlock
Steering system 2F-9
from wrong pulling during the repair of
vehicle.
Removal and installation of steering gear
and connecting rod
Note:
●
In case of not removing the wheel speed
sensor from ABS system, carry out the
following operation. When the wire is
wrongly pulled, it may cause the broken
circuit of wire. Before carrying out the
following operation procedures, remove
wheel speed sensor (from axle side), and
place it in appropriate position to prevent it
1.
Remove front exhaust pipe fixing rubber
sleeve. (refer to the exhaust system,
removal/installation of exhaust system).
2.
Remove it in the sequence shown in the table.
3.
Install it in the reverse sequence of removal.
4.
After installing it, check the toe-in of wheel
(refer to the location of wheel, location of
front wheel).
1
Bolt(telescopic shaft) refer to its removal instructions; refer to its installation instructions.
2
Split pin
3
Flange nut
4
Steering tie rod tail end ball head: refer to its removal instructions; refer to its removal
instructions.
5
Oil return pipe
6
High-pressure oil pipe
7
Bolt(reinforced plate)
8
Nut(reinforced plate)
9
For steering gear and joint, refer to their removal instructions.
10
Dust cover
Steering system 2F-10
Keypoints for removing the bolt (telescopic shaft)
Make the aligning marks of gear shaft and gear
chamber for the purpose of correct installation.
Keypoints for installing the bolt (telescopic shaft)
After aligning the marks, install the intermediate
shaft and bolt.
Keypoints for removing the Steering tie rod tail
end ball head
1.
Remove the end rod nut.
2.
Remove the end post from steering knuckle
with a special tool.
Keypoints for removing the steering gear and
joint
Draw the steering gear and joint out of right side.
Steering system 2F-11
Disassembly of steering gear and connecting rod
1.
Disassemble it in the sequence shown in the table.
1
Heat shield
21
Assembly of control valve
2
Oil pipe 1
22
Seal ring
3
Oil pipe 2
23
Gear shaft
4
Steering tie rod tail end
24
Valve chamber assembly
5
Lock nut(end post head)
25
Upper bearing: refer to its disassembly
instructions.
6
Spring clip
26
Oil seal: refer to its disassembly instructions.
7
Dust jacket wire
27
Valve chamber
8
Dust jacket
28
Supporting block: refer to its disassembly
instructions.
9
Steering tie rod: refer to its disassembly
instructions.
29
U tie
10
Washer
30
“O” ring
11
Lock nut (adjusting cover) : refer to its
disassembly instructions.
31
Steering rack
12
Adjusting cover: refer to its disassembly
instructions.
32
Seal ring
13
Hold down spring
33
“O” ring
14
Limit washer
34
Inner guide sleeve: refer to its disassembly
instructions.
15
“O”ring
35
Oil seal: refer to its disassembly instructions.
16
Dust cover
36
Fixed support
17
Socket bolt
37
Cushion block
18
Assembly of gear shaft and gear chamber:
refer to its disassembly instructions.
38
Rubber cushion block: refer to its disassembly
instructions.
19
Gear shaft assembly
39
Gearbox
20
Snap ring:
instructions.
40
Steering tie rod ball head gasket: refer to its
disassembly instructions.
refer
to
its
disassembly
Steering system 2F-12
Keypoints for disassembling the steering tie rod
1.
Remove the dust jacket.
2.
Remove the steering tie rod.
Keypoints for disassembling the lock nut
(adjusting cover)
Remove the lock nut with a special tool.
Assembly of gear shaft and valve chamber
1.
Remove the bolts connected to gear shaft and
valve chamber (2 pcs).
2.
As shown in the figure, grasp the gear shaft,
and pull out the assembly of gear shaft and
gear chamber.
Keypoints for disassembling the gear shaft
assembly
●
If the gear shaft is difficult to pull out, remove
it by pressing it down.
Push the gear shaft out of valve chamber, as shown
in the figure.
Steering system 2F-13
Snap spring
Keypoints for disassembling the snap spring
Remove the snap spring carefully, and don’t
damage the gear shaft assembly.
Guide shaft
shoulder
Keypoints for disassembling the upper bearing
and oil seal
1.
Install the special tool as shown in the figure.
2.
Press out the oil seal and upper bearing with a
special tool, and don’t press the edges of valve
chamber.
Keypoints for disassembling the hoop
Drill the surface part padded with anvil by adopting
a drill.
Note:
●
Pull out the hoop carefully, and don’t damage
the U tie.
●
Remove the hoop with a special tool.
Steering system 2F-14
Keypoints for disassembling the inner guide
sleeve and oil seal
1.
Attach the special tool to the side of valve.
2.
Install the special tool into the gear chamber.
3.
Press out the oil seal and inner guide sleeve.
Keypoints for removing the rubber cushion
block
Press the rubber cushion block out of gear chamber
with a special tool and press.
Keypoints for disassembling the steering tie rod
end gasket
1.
Place and clamp the end of tie rod in the
fixture.
2.
Clamp the end of tie rod at the shown angle,
and align the chisel to end shim.
3.
Hit the chisel with a hammer to remove the end
shim.
Check of steering gear and connecting rod
Check of rack
1.
Check the rack for fracture, damages or broken
teeth, etc.

If any, replace the rack.
2.
Measure the radial runout of rack. If not within
the specified range, replace the rack. Radial
runout
Near to A point: 0.15mm{0.006 in}
Near to B point: 0.20mm{0.008 in}
Steering system 2F-15
Check of steering tie rod end
1.
Check the tie rod end for damages or rubber
sleeve for cracks.
2.
Replace if necessary.
3.
Check the ball joint for loosening.
4.
Replace the tie rod end if necessary.
5.
Turn the ball head five times.
6.
Measure the rotation torque of ball head with a
special tool and spring.
•
If not within the specified range, replace the tie
rod end. Rotation torque:
0. 4-2.7N.m{3.5-26.0kgf.cm, 3.1-22.5in.lbf}
Reading of spring balance:
3. 4-25.5N{0.35-2.60kgf, 0.8-5.71bf}
Check of steering tie rod
1.
Check the tie rod for bends or damages, and
replace it if necessary.
2.
Check the ball joint for loosening, and replace
it if necessary.
3.
Swing the tie rod back and forth five times.
4.
Measure the swing torque with a spring
balance.
If the torque is not within the specified range,
replace the tie rod.
Swing torque:
0. 1-4. 0N·m(1-39kgf.cm, 0. 9-30. 8in.lbf}
Reading of spring balance:
0. 6-24. 5N.m{0. 06-2. 50kgf, 0. 13-5. 501bf}
Steering system 2F-16
Assembling of steering gear and connecting rod
1.
Assemble them in the sequence shown in the table.
1
Tie rod end rubber sleeve: refer to its
installation instructions.
20
Snap ring
2
Supporting rubber block: refer to its installation
instructions.
21
Socket sleeve bolt
3
Gearbox
22
Dust cover
4
Supporting block
23
“O” ring
5
Supporting block bracket
24
Limit washer
6
Oil seal: refer to its installation instructions.
25
Hold down spring
7
Bush: refer to its installation instructions.
26
Adjusting cover:
instructions.
8
“O” ring
27
Lock nut(adjusting cover)
9
Seal ring
28
Washer
10
Steering rack
29
Tie rod
11
“O” ring
30
Dust jacket
12
U seal gasket
31
Dust jacket wire
13
Hoop: refer to its installation instructions.
32
Spring clip
14
Valve chamber
33
Lock nut(tie rod end)
15
Oil seal: refer to its installation instructions.
34
Tie rod end
16
Upper bearing:
instructions.
35
Oil pipe 1
17
Gear shaft
36
Oil pipe 2
18
Seal ring: refer to its installation instructions.
37
Heat shield
19
Control valve
refer
to
its
installation
refer
to
its
installation
Steering system 2F-17
Keypoints for installing the tie rod end rubber
sleeve
1.
Wipe off the oil dirt from the ball joint.
2.
Put a little of grease into new dust jacket.
3.
Install the dust jacket on the end of tie rod with
a special tool and press.
4.
Wipe off all the exposed grease.
Keypoints for installing the supporting rubber
block
Rubber mat
Steel pipe
1.
Apply the soap water to the rubber of
supporting block.
2.
Press the rubber support block with a special
tool and press, until the rubber end comes out
of gear chamber.
3.
Turn back the gear chamber, and press the
rubber supporting block, until the rubber block
comes out of its other side.
4.
Align the rubber supporting block to steel pipe.
The rubber block end is
aligned to steel pipe.
Oil seal
Attentions for installing the oil seal and bush
1.
Install a new “O” ring and seal ring on the rack
lever.
2.
After installing the seal ring, make it tightly
affix the lever.
3.
Attach a new oil seal to (49B032 325) with a
special tool (49 B032 324).
Steering system 2F-18
4.
Remove the special tool (49B032325).
5.
Place the oil seal on the edge of rack lever with
a special tool, and remove the special tool.
6.
Attach a new bush to steering rack.
Note:
●
While pressing it in, the applied force shall not
exceed 39kpa{400kg}cm2, 5688psi} to avoid
the damages of oil seal and bush.
●
Apply a little of grease to the seal ring and oil
seal bush.
7.
Install the steering rack into gearbox, and press
in the oil seal and bush with a special tool, until
it’s difficult to press.
Keypoints for installing the hoop
1.
Apply a little of lubricating oil to “O” ring and
U seal gasket.
2.
Install “O” ring and U seal gasket on the socket
sleeve.
3.
Install them on the steering gear with a special
tool.
4.
Install the hoop with a special tool.
5.
Fix the hoop on cylinder body with a chisel.
Steering system 2F-19
Keypoints for installing the oil seal
1.
Apply the appropriate amount of grease to new
oil seal.
2.
Press in the new oil seal with a special tool.
Keypoints for installing upper bearing
1.
Apply the appropriate amount of grease to new
upper bearing.
2.
Press in the bearing with a special tool.
1.
Attach a new seal ring to the valve body of
gear shaft with a special tool.
2.
After the installation, place the seal ring in
position with a special tool.
3.
Install the snap ring.
Keypoints for installing the adjusting cover
1.
Place the rack in middle position.
2.
Tighten the adjusting cover up to its tightening
torque of 19.6N.m{2.0kgf.m} three times, and
then turn the end cover by 23° with a special
tool.
[Reading of spring balance]9.9-13.7N{1.0-1.4kgf}
Install the lock nut with a special tool.
Tightening torque: 40-49N·m{4. 0-5.0kgf.m}
Check of air tightness
1.
Connect the special tool to the gear chamber
booster cylinder.
2.
Apply a vacuum pressure of 53.3kpa
{400mmHg,15.7inHg) to cylinder with a
vacuum pump, and ensure that its vacuum
pressure can be kept for at least 30s.
●
If this vacuum pressure can’t be kept, replace
the oil seal.
Steering system 2F-20
Removal and installation of power steering pump
1.
Remove it in the sequence shown in the table.
2.
Install it in the reverse sequence of removal.
1
Adjusting bolt
2
Tightening bolt
3
Drive belt
4
Pressure switch plug
5
High-pressure pipe
6
Oil suction hose
7
Oil pump and support
3.
Adjust the drive belt (refer to the drive belt,
adjustment of drive belt).
Steering system 2F-21
Disassembly and assembly of power steering pump
Note:
●
The following operation can be performed only after replacing “O”ring and oil seal. If it’s still
required to check other items, replace the pump body assembly.
1.
Disassemble it in the sequence shown in the table.
2.
Assemble it in the reverse sequence of disassembly.
1
Power steering pump assembly: refer to
its disassembly instructions.
9
Cam ring:
instructions.
2
Bolt
10
Snap ring
3
Oil suction pipe
11
Rotor
4
O ring
12
Impeller: refer
instructions.
5
Pressure switch
13
Front pump body
6
Rear pump body: refer to its assembling
instructions.
14
Shaft assembly
7
O ring
15
Oil seal: refer
instructions.
8
Side disc
refer
to
to
to
its
installation
its
assembling
its
assembling
Steering system 2F-22
Keypoints for disassembling the power steering
pump assembly
Note:
●
While clamping the assembly with a vice, fix,
remove and assemble it with a special tool to
avoid the damages of oil pump.
Keypoints for installing the oil seal
Note:
●
Locate the pump body. Install the oil seal with
a special tool and hammer.
Keypoints for installing the blade
Place the blade inside the rotor, the round edge of
blade shall contact with that of inner cam ring.
Keypoints for installing inner cam ring
With the mark up, install the inner cam ring into
front pump body.
Keypoints for installing rear pump body
After installing rear pump body, turn the wheel shaft
by hands, and observe whether it rotates smoothly.
Brake system 2F-1
Chapter 15
Brake system
General and operation ............................................................................................................................ 2F-2
Operation of brake caution light........................................................................................................ 2F-2
Description of ABS fault light .......................................................................................................... 2F-2
Description of ESP fault light ........................................................................................................... 2F-2
Description of ESP-OFF switch indicator lamp................................................................................ 2F-2
Parts of brake system.............................................................................................................................. 2F-3
Diagnostic data and procedures......................................................................................................... 2F-5
Faults of brake system....................................................................................................................... 2F-6
Manual exhaustion ............................................................................................................................ 2F-6
Check of pedal stroke........................................................................................................................ 2F-7
Check of brake pedal free stroke....................................................................................................... 2F-7
Repair instructions ............................................................................................................................ 2F-8
Specifications .................................................................................................................................. 2F-10
Circuit diagram.................................................................................................................................2F-11
Repair of parts....................................................................................................................................... 2F-12
Brake master cylinder with oil cup.................................................................................................. 2F-12
Diagnostic references and procedures............................................................................................. 2F-12
Brake master cylinder with brake fluid reservoir assembly ............................................................ 2F-12
Specifications .................................................................................................................................. 2F-13
Vacuum booster .............................................................................................................................. 2F-13
Check of vacuum ................................................................................................................................... 2F-13
Repair instructions .......................................................................................................................... 2F-14
Front and rear brakes....................................................................................................................... 2F-15
Check of front-disc brake................................................................................................................ 2F-16
Removal and installation of Front-disc brake ................................................................................. 2F-18
Check of rear-drum brake ............................................................................................................... 2F-20
Removal and installation of rear-drum brake.................................................................................. 2F-21
Check of rear-disc brake ................................................................................................................. 2F-23
Removal and installation of rear-disc brake.................................................................................... 2F-24
Parking brake system............................................................................................................................ 2F-25
General and operation ..................................................................................................................... 2F-25
Structure diagram ............................................................................................................................ 2F-25
Repair instructions .......................................................................................................................... 2F-25
Parameters ............................................................................................................................................. 2F-27
General technical parameters .......................................................................................................... 2F-27
Locking torque parameters.............................................................................................................. 2F-27
Brake system 2F-2
ABS system ............................................................................................................................................ 2F-27
Overview ................................................................................................................................................ 2F-27
I. Attentions..................................................................................................................................... 2F-27
II. Initial check ................................................................................................................................ 2F-29
Introduction of ABS 9 system .............................................................................................................. 2F-31
I. Composition of ABS 9 system..................................................................................................... 2F-31
II. Hydraulic diagram for Haima M3 ABS 9 X-type arrangement.................................................. 2F-31
III. Haima M3 ABS 9 ECU interface circuit................................................................................... 2F-33
Fault diagnosis....................................................................................................................................... 2F-35
I. Diagnostic flow............................................................................................................................ 2F-35
II. For the faults without fault codes, repair it................................................................................. 2F-36
III. Repair of occasional faults ........................................................................................................ 2F-37
IV. Analysis of fault codes.............................................................................................................. 2F-38
Removal and installation ...................................................................................................................... 2F-44
I. Steps for removing ABS assembly .............................................................................................. 2F-44
II. Installation steps of ABS assembly ............................................................................................ 2F-44
III. Cross validation......................................................................................................................... 2F-44
IV. Exhaust instructions .................................................................................................................. 2F-44
Summary................................................................................................................................................ 2F-47
I. Attentions..................................................................................................................................... 2F-47
II. Initial check ................................................................................................................................ 2F-49
Introduction of ESP 9 system ............................................................................................................... 2F-51
I. Composition of ESP 9 system...................................................................................................... 2F-51
II. Hydraulic diagram for ESP 9...................................................................................................... 2F-52
III.Haima M3 ESP 9 ECU interface circuit..................................................................................... 2F-53
Fault diagnosis....................................................................................................................................... 2F-55
I. Diagnostic flow............................................................................................................................ 2F-55
II. For the faults without fault codes, repair it................................................................................. 2F-56
III. Repair of occasional faults ........................................................................................................ 2F-56
IV. Analysis of fault codes.............................................................................................................. 2F-57
Removal and installation ...................................................................................................................... 2F-62
I. Steps for removing ESP assembly ............................................................................................... 2F-62
II. Installation steps of ESP assembly ............................................................................................. 2F-62
III. Exhaust instructions .................................................................................................................. 2F-62
IV. Instructions for calibrating the integrated inertial sensor (ESP9i system) ................................ 2F-64
Brake system 2F-2
General and operation
Operation of brake caution light
The brake caution light (BRAKE)
applied in
this brake system is located inside the instrument
panel. When the ignition switch is in ON gear, the
brake caution light will go on. When the ignition
switch returns to ACC gear, the caution light will
go out. The following cases will make the caution
light go on.
●
In case of applying the parking brake when
the ignition switch is in ON gear, the caution
light will go on.
●
When the level of brake fluid is below a
caution light will
certain value, “BRAKE”
go on.
Description of ESP fault light
ESP fault light
applied in this brake system
is located inside the instrument panel (as shown in
the figure).
ESP self-check: when the ignition switch is turned
from ACC to ON, the self-check of ESP is started,
and the fault light goes on at this time. After
finishing its self-check, the fault light goes out, and
it certifies the normality of ESP system; if it’s
constantly on, ESP system will be faulty, and the
professionals are required to check the faults of
ESP system (for its details, see the description of
ESP anti-lock system repair).
Description of ABS fault light
ABS fault light
applied in this brake system is
located inside the instrument panel (as shown in
the figure).
Self-check of ABS: when the ignition switch is
turned from ACC to ON, the self-check of ABS is
started, and the fault light goes on. After finishing
its self-check within 0.7 to 3s, the fault light goes
out, it certifies the normality of ABS system; if it’s
constantly on, ABS system will be faulty, and the
professionals are required to check the faults of
ABS system (for its details, see the description of
ABS anti-lock system repair).
Description of ESP-OFF switch indicator
lamp
ESP manual switch indicator lamp
applied in
this brake system is located inside the instrument
panel (as shown in the figure).
goes on, it indicates the
When ESP-OFF light
functions of ESP is manually closed, its functions
can be started with ESP switch button, and ESPOFF light
will go out after starting it.
Brake system 2F-3
Parts of brake system
Brake system (I)
Brake system(with ABS)
1. Front steering knuckle
with brake assembly(right)
14. Front brake pipe(left)
26. Pin shaft
15. Brake master cylinder
rear chamber oil pipe
assembly
27. Split pin
29. Flange nut
4. Elastic card
16. brake master cylinder
front chamber oil pipe
assembly
5. Pipe clamp B
17. Combination nut
6. Lock bolt
18. Lock bolt
7. Vacuum power-assisting
hose assembly
19. ABS support
32. Parking brake handle
assembly
20. ABS support cushion
33. Lock bolt
21. ASB controller
34. Parking cable assembly
(right)
9. Front wheel speed sensor
support (left)
22. Rear brake pipe front
section (left)
35. Lock bolt
10. lock bolt
23. Front brake pipe(right)
36 .parking cable assembly
(left)
11. Hollow bolt
24. Front steering knuckle
with brake assembly(right)
37. Pipe clamp E
2. Front brake hose assembly
3. Front wheel
sensor(right)
8. Front
sensor(left)
wheel
speed
speed
12. Washer
13. Rear brake pipe front
section(right)
25. With master cylinder
vacuum booster assembly
28. Brake pedal assembly
40.
Rear-drum
brake
assembly(left or right)
41. Hexagon flange bolt
42. Rear wheel speed sensor
30. Lock bolt
43. Rear brake pipe rear
section (left or right)
31. Vacuum power-assisting
hose assembly
44.
Rear
assembly
38. Pipe clamp F
39. Pipe clamp A
brake
hose
Brake system 2F-4
Brake system (II)
Brake system(with ESP)
1. Front steering knuckle
with brake assembly(right)
2. Front
assembly
brake
hose
3. Front wheel
sensor(right)
speed
4. elastic card
5. pipe clamp B
6. lock bolt
7. vacuum power-assisting
hose assembly
8. Front wheel
sensor(left)
speed
9. front wheel speed sensor
support (left)
10. lock bolt
11. hollow bolt
12. washer
13. Front brake pipe(right)
14. brake master cylinder
rear chamber oil pipe
assembly
24. Front steering knuckle
with brake assembly(right)
36. Parking cable assembly
(left)
25. With master cylinder
vacuum booster assembly
37. Pipe clamp E
38. Pipe clamp F
15. Brake master cylinder
front chamber oil pipe
assembly
26. Pin shaft
16. ESP controller
28. brake pedal assembly
40.
Rear-disc
assembly(left or right)
17. Lock bolt
29. flange nut
41. Rear brake hose assembly
18. ESP upper support,
ESP lower support
30. lock bolt
42. Rear wheel speed sensor
31. Vacuum power-assisting
hose assembly
43. Hexagon flange bolt
19. combination nut
20. Rear brake pipe front
section (left)
32. parking brake handle
assembly
21. Rear brake pipe front
section(right)
33. lock bolt
39. Pipe clamp A
27. split pin
22. front brake pipe(left)
34
.parking
assembly(right)
23. steering angle sensor
35. Lock bolt
cable
brake
Brake system 2F-5
cylinder, it indicates the leakage of master
cylinder, but its problems can’t be explained
only as per the wetting conditions of master
cylinder.
Diagnostic data and procedures
Brake system test
The brake test must be performed on dry, clean and
flat road without slope. If the road surface is wet
and slippy, oil dirty or soft, the vehicle can’t stick
to the ground evenly, thus its real braking
performance can’t be tested.
The brake test shall be performed with lighter and
heavier pedal-applying forces at different speeds,
but the lock of brake and slippage of vehicle must
be avoided. Even if the vehicle is braked with a
large force, its lock and slippage can show its
braking ability. During the rotation of wheel, its
braking distance is less than the one while it’s
locked, the friction force between the wheel and
ground is also below the force of wheel while it’s
slipped. The higher its deceleration speed is, the
higher the required brake pedal force is. Three key
external factors can influence its braking ability:



The uneven adhesion between the tire and
ground will lead to uneven braking force, the
air pressures of left and right tires shall be
equal to each other, and the patterns of left
and right tires shall be the same.
Uneven load will also influence its braking
ability, because the wheel with higher load
requires a higher braking input force than any
other wheel, so it can also produce a higher
braking force.
Projected or unflat road surface will cause the
runout of brake.
Check of brake fluid leakage: make the engine
idling, put the gear in neutral gear, and step down
the brake pedal with a consistent force. If the pedal
sinks, the hydraulic system may be leaked, so the
system shall be checked.
Check of fluid level in master cylinder fluid
reservoir: the slow drop of fluid in fluid reservoir
is caused by normal wears of friction liner.
However, its fluid level shows very low, it
indicates the leakage of system. The system may
be internally or externally leaked. Sometimes, if no
faults of system are found out during the following
check, it may be slightly leaked. If its fluid level is
normal, check the length of vacuum booster
pushrod. In case of finding out the improper length
of pushrod, adjust or replace the pushrod.
Check the master cylinder
following procedures:

through
the
Check the casting cracks of master cylinder or
leakage of brake fluid around it. If at least one
drop of brake fluid exists outside the master

Check the lengths of linkage and pushrod
connected to the pedal. If these two parts
don’t conform to the requirements,
disassemble the master cylinder, and check
whether the leather cup is extended or
expanded. If it’s expanded, the brake fluid
may be unqualified or polluted. In case of
confirming the pollution of brake fluid, all the
parts shall be removed for cleaning, and all
the brake pipes must be also cleaned.
Unqualified brake fluid, other mineral oil or water
in brake fluid will cause the gasification of brake
fluid or deterioration of rubber parts,e.g. the
expansion of master cylinder piston rubber cup
indicates the deterioration of rubber part.
Meanwhile, the same case also occurs to the brake
slave cylinder rubber cup.
In case of finding out the deterioration of rubber
parts, disassemble all the hydraulic parts, and clean
themwith alcohol; blow the alcohol dry with
compressed air before reassembling them, and
replace all the rubber parts from the system,
including the hose.
Check of brake hose
The hydraulic brake hose shall be checked at least
once every two years. After the occurrence of
accidental damages, broken surface scratches,
leakage or bubbles, the hose must be also checked.
Check the trends and fixing conditions of hose. If
the friction of brake hose with other parts occurs, it
will lead to final failure of surface damages, and its
check may require a mirror or light. If the above
cases are found, the hose must be adjusted or
replaced.
Operation of caution light
exists
A warning indicator lamp “BRAKE
on the panel of brake system. When the ignition
switch is in Position III, the warning lamp will go
on. When the switch is in position II, the warning
lamp will go out.
If the following cases occur, the warning lamp will
give an alarm:

Application of parking brake: in case of
applying the parking brake, the ignition
switch is in position II at this time, the
warning lamp will go on. When the level of
brake fluid is overlow: when the level of fluid
in fluid reservoir is overlow, the warning
lamp will go on.
Brake system 2F-6
Faults of brake system
Fault symptom
The brake warning lamp is
constantly on.
The brake lamp goes on.
Cause
Remedy
Leakage of brake fluid
Repair or add in the brake fluid.
Short circuit of parking brake
switch
Repair its short circuit part.
Fault of fluid level sensor
Replace the sensor.
Fault of brake lamp switch
Replace the brake lamp switch.
Too short length of pushrod
Adjust the length of vacuum
booster pushrod.
Short circuit of brake lamp switch
Repair its short-circuit part.
Lack or leakage of brake fluid
Repair or add in brake fluid.
Pollution of brake fluid
Replace the brake fluid.
Air in brake system
Drain the fluid out of brake
system again.
Damages of brake pipe
Replace the brake pipe.
Damages of vacuum powerassisting hose or non-return valve
Replace the vacuum powerassisting hose or non-return valve.
Seizure of brake pedal
Replace the brake pedal.
Fault of caliper piston return
Replace the return rubber ring.
Fault of brake master cylinder
Replace
cylinder.
Air in brake system
Exhaust the air.
Insufficiency or leakage of brake
fluid
Replace the leaked part or add in
the brake fluid.
Overlong free stroke of brake pedal
Adjust the length of vacuum
booster pushrod.
Insufficient braking force
Braking drag
Overlong stroke of pedal
Important hints: the sequence of exhaustion: left
rear, left front, right front, right rear. During the
drainage of fluid, check the level of fluid
continually, and add in the brake fluid.
Lift up the vehicle.
2.
Loosen the bleed bolt and dust cover.
3.
Connect a transparent pipe to bleed screw,
brake
master
and make its other end soaked in the brake
fluid of transparent container.
Manual exhaustion
1.
the
4.
After stepping the brake pedal slowly several
times, keep it stepped.
5.
Loosen the bleed screw, drain the brake fluid,
and then tighten the screw.
Note: Step the pedal until the bleed screw is
Brake system 2F-7
tightened.
6.
Repeat Steps 4 and 5 until all the air is bled.
7.
Check whether the bleed screw is tightened.
overlong stroke of vacuum booster pushrod,
but this case seldom occurs.
5.
Check of pedal stroke
After removing the brake drum, check the
automatic clearance regulator. If it’s damaged,
repair or replace it.
1.
Start the engine.
Check of brake pedal free stroke
2.
Step down the pedal three times.
1.
3.
Step down the brake pedal with about 30Kg
(66.15Ib) force, and measure the distance
between the pedal and the lowest part of front
barrier.
Step the brake pedal several times to
eliminate the vacuum of vacuum booster.
2.
Push the brake pedal by hands, and measure
the stroke of pedal from its free state to
hardening position.
Unit: mm
Parameter
Unit: mm
60
Specified value
3.
4.
If the distance is below 60mm(2.36in.), it may
be caused by the worn size of rear brake shoe
over its specified value or existence of air in
the pipe. After replacing the brake shoe and
bleeding all the air, if the distance is still
below 60mm (2.36in.), it may be caused by
the faults of rear brake shoe regulator or
5-10
The free stroke of brake pedal can’t be
adjusted.
Brake system 2F-8
Repair instructions
(I)
Repair on the vehicle
Rear brake hose
Removal procedures:
Front brake hose
Procedures for removing:
1.
Remove the wheel.
2.
Remove the brake hose.
●
Loosen the connector ① connected to brake
pipe.
●
Block the opening of brake pipe, and avoid
the loss and pollution of brake fluid.
●
Remove the snap spring ②.
●
Loosen the connecting bolt ③.
●
Remove the brake hose from the support.
●
Loosen the connecting bolt ④.
①
Remove the wheel,
②
Remove the brake hose.
●
Loosen the connector connected to brake pipe
①.
●
Remove the snap spring ②.
●
Block the opening of brake pipe, and avoid
the loss and pollution of brake fluid.
Installation procedures:
1.
Connect the brake hose to pipe ①. Tightening
torque: 14 to 18N·m.
2.
Install the snap spring ②.
3.
Install the brake hose connecting bolt ④.
Tightening torque: 25. 5N·m.
Important: please apply the brake
recommended by Sino Maersk Co., Ltd.
4.
fluid
Exhaust the brake system. Refer to manual
exhaustion in this chapter.
5.
Confirm whether the brake system is leaked.
6.
Install the wheel.
Installation procedures:
1.
Connect the brake hose to the pipe.
Tightening torque: 14 to 18N·m (12 Ib-ft).
2.
Install the snap spring.
Important: please apply only the recommended
brake fluid.
3.
Exhaust the brake system. Refer to manual
exhaustion in this chapter.
4.
Confirm whether the brake system is leaked.
5.
Install the wheel.
Brake system 2F-9
Brake lamp switch
Removal procedures:
1.
Disconnect the negative cable of battery.
2.
Remove the brake lamp switch.
●
Pull down the plug ①.
●
Turn and take down the brake lamp switch ②.
Installation procedures:
1.
Install the brake lamp switch.
2.
Connect the plug.
3.
Connect the negative cable of battery.
Important: after installing the brake lamp switch,
be sure to pull the tie rod fully.
Fig.1
Brake pedal
Removal procedures:
1.
Remove the brake lamp switch.
2.
Pull out the split pin ①, take down the pin
shaft ②, and disconnect the connection of
vacuum booster and brake pedal.
3.
Remove the bolt ③.
4.
Remove the lock nut, and take down the pedal
assembly.
5.
Removal of pedal assembly (see Fig.2)
Fig.2
Loosen the lock nut ①, and pull out the pin shaft
②.
Take down the pedal arm ③, and pull out the
fixing shaft sleeves ④ and ⑤.
Take down the brake lamp lower limit cushion ⑥.
Take down the brake pedal liner ⑦.
Fig.3
Assembling procedures:
1.
Install the pedal liner ⑦ and brake lamp
lower limit cushion ⑥.
2.
Install the fixing shaft sleeves ④ and ⑤,
pedal arm ③ and pin shaft ②.
3.
Tighten the lock nut ①.
Tightening torque: 22Nm(13 IB-ft).
4.
Connect the vacuum booster and brake pedal.
5.
Install the brake lamp switch.
Brake system 2F-10
Specifications
General parameters
Item
mm
Diameter of brake disc
φ256
Thickness of brake disc
24
Valid thickness of disc
22
Diameter of caliper cylinder
φ54
Front brake
Rear-drum brake
Specification
Φ203×36. 5
wheel cylinder diameter
Φ19. 05/
Φ20. 64(proportional valve)
Inner diameter of brake drum
Φ203
Rear-disc brake
Diameter of brake disc
φ250
Thickness of brake disc
10
Valid thickness of disc
8
caliper cylinder diameter
φ34
Vacuum booster with brake master cylinder assembly
Assist rate
5
diameter of master cylinder
20.64
Stroke of master cylinder
18+18
Brake pedal
free stroke
6-10
Valid stroke
120
brake fluid
Type
DOT-3
Capacity
300ml±20ml
Tightening torque specifications of fasteners
Application
N·m
Install the brake oil pipe at the joint of
brake oil pipe.
14 to 18
Mounting bolt of front brake hose and
caliper
22 to 30
Connecting bolt of brake pedal and pedal
support
19 to 25
brake hose support tightening bolt
8 to 14
Connecting bolt of wheel speed sensor
support
8 to 14
ABS/ESP/proportional
mounting bolt
20 to 24
valve
support
Brake system 2F-11
Circuit diagram
Circuit diagram of brake warning lamp
Battery
ABS control unit
Brake switch
High-mounted brake lamp
Left brake lamp
Right brake lamp
Brake system 2F-12
Repair of parts
Brake master cylinder with brake fluid
reservoir assembly
Brake master cylinder with oil cup
General and operation
Brake master cylinder
The brake master cylinder is designed as per the
shunt of system. The braking pressure of right
front wheel brake and left rear wheel brake is
supplied by the first chamber, and that of left front
wheel brake and right rear wheel brake is supplied
by the second chamber.
Note:
Removal procedures:

During the replacement of master cylinder,
replace the master cylinder assembly. If the
hydraulic parts are removed or separated, the
fluid of all or a part of brake systems must be
drained.
1.
Remove the brake fluid reservoir.

Pull out the brake fluid level alarm switch ①
and clutch oil inlet hose ②.

Block the clutch oil outlet;

The torque shall be achieved on the dry and
non-lubricated fastener.

Take down the fixing screw rod ③ with a
cross screwdriver;

All the operations must be performed on clean
platform to avoid all the mineral oils.

Pull out brake fluid reservoir violently.
2.
Remove the master cylinder.
Liquid level sensor

Loosen the brake oil pipe joint ④;
Liquid level sensor is stuck to the liquid reservoir.
When the brake fluid is below the liquid level line,
this sensor activates the brake lamp. When the
level of brake fluid becomes normal, the brake
lamp will go out.
Block the opening of master cylinder to avoid the
outflow and pollution of brake fluid;
Diagnostic references and procedures

Remove the master cylinder connected to
vacuum booster ⑦;
Note: the brake fluid will damage the paint. If the
fluid overflows to the paint surface, flush it
immediately with cold water.
Installation procedures
Note: apply only the specified brake fluid.
Check of brake fluid level
1.
Check the liquid level.
2.
If the liquid level is below MIN line, add in
the brake fluid up to MAX.
1.
Install master cylinder assembly with a nut.
Tightening torque: 16N·m.
2.
Connect the fluid reservoir and brake master
cylinder.
3.
Connect the brake pipe and master cylinder.
Tightening torque: 17N·m.
4.
Exhaust the brake system.
Brake system 2F-13
Specifications
General requirements
Application
Master
cylinder
Unit
Value
Type
-
Tandem
Hole
diameter
mm(in)
20.64(0.81)
Tightening torque specifications of fasteners
Application
N·m
Fluid reservoir mounting screw
10
Master cylinder mounting nut
22
Connection of brake oil pipe
and master cylinder
17
Connection of brake oil pipe
and proportional valve
17
Brake oil pipe and rear wheel
cylinder
17
Connection of brake oil pipe
and front brake caliper
17
In case of finding out any problem, check the
check valve and vacuum hose for damages, check
their installation, repair and recheck them if
necessary.
Step 3
1.
Start the engine.
2.
Step down the brake pedal with a common
force.
3.
Keep the brake pedal in stepped position, and
stop the engine.
4.
Keep the brake pedal in stepped position for
about 30s.
5.
If the height of brake pedal is unchanged, it
indicates that the vacuum booster is running.
Check of vacuum booster functions (check them
with a measuring instrument)
1.
As shown in the figure, separately connect
SST, vacuum gauge and pedal pressure
detector.
Note:

Vacuum booster
Check of vacuum booster
Adopt a special instrument and pedal pressure
detector. Bleed the air out of SST at
instrument A.
Check of vacuum booster functions(simple
methods)
Note:

Pedal pressure gauge
Replace the vacuum booster if necessary.
Step 1
1.
Stop the engine, and step down the brake
pedal several times.
2.
Keep stepping down the brake pedal, and start
the engine.
2.
If the pedal moves down slightly immediately
after starting the engine, it indicates that the
vacuum booster is running.
Check of vacuum
3.
Vacuum gauge
After bleeding the air out of SST, check it as
per the following steps.
Step 2
Leakage and non-load
1.
Start the engine.
1.
Start the engine.
2.
After running the engine for 1 or 2 minutes,
stop the engine.
2.
When the reading of vacuum gauge reaches
66.7kPa {500mmHg}, stop the engine.
3.
Step down the brake pedal with a common
force.
3.
4.
If the first pedal stroke is long and the
following stroke of stepped pedal becomes
shortened, it indicates that the surface vacuum
booster pump is running.
Close the vacuum gauge for15s. If the
vacuum pressure shows 63.3-66.7kPa {475500mmHg}, it indicates the normal operation
of vacuum booster.
Note:
Loading conditions
1.
Start the engine.
Brake system 2F-14
2.
Step down the brake pedal with a force of
196N {20kgf}.
3.
Keep stepping down the brake pedal. When
the reading of vacuum gauge is up to 66.7kPa
{500mmHg}, stop the engine.
4.
Observe the vacuum gauge for 15s. If the
vacuum pressure indicates 63.3-66.7kPa
{475-500mmHg}, it indicates the normal
operation of vacuum booster.
reaches 66. 7kPa{500mmHg}, step down the
brake pedal.

If the pressure of fluid is within the specified
range at this time, it indicates the normal
operation of brake device.
Pedal pressure
196N{20kgf}
Check of hydraulic system
1.
3.
Fluid pressure
790kPa{8kgf/cm2}min
Pedal
pressure
Stop the engine (vacuum pressure of
0kPa{0mmHg}. If the pressure of fluid is
within the specified range at this time, it
indicates the normal operation of vacuum
booster.
Fluid pressure
MTX
196N
7,100kPa{72kgf/cm2}min
ATX
{20kgf}
8,820kPa{90kgf/cm2}min
Start the engine. When its vacuum pressure
Repair instructions
Vacuum
suction port
of engine
Vacuum hose and check valve:
Installation procedures
I)
Vacuum hose
1.
Loosen③ and ⑥ with calipers or hoop special
tool, pull the hoses separately out of engine
vacuum suction inlet and non-return valve
joint;
2.
Loosen the connecting bolt ⑤ with a wrench;
3.
Take down the vacuum hose.
II) Non-return valve.
1.
Loosen ③ and pull out the vacuum hose ④
with calipers or special tool;
2.
Pull the non-return valve from the booster
housing violently.
Brake system 2F-15
Vacuum booster assembly
3.
Connect the vacuum power-assisting hose and
clutch oil inlet hose to the vacuum booster.
4.
Connect the brake pipe and brake master
cylinder, and tighten the oil pipe joint up to
17N·m.
Removal procedures:
1.
First
remove
the
air
filter,
ABS/ESP/proportional valve, support and
relevant pipes;
1.
Loosen the hoop, and pull out the vacuum
power-assisting hose ⑥ and clutch oil inlet
hose ④ with calipers;
2.
Loosen the oil pipe connector connected to
brake master cylinder, and block the oil outlet
of master cylinder with a drain plug;
3.
Pull out the split pin ①, take down the pin
shaft ②, and remove the nut ③ with a tool;
4.
Take down the vacuum booster with master
cylinder assembly.
Specifications
Requirements for tightening torque
Application
N·m
vacuum booster and front
boarding mounting nut
22
master cylinder mounting nut
17
Front and rear brakes
General and operation
Installation procedures:
Brake caliper assembly
1.
After connecting “Booster assembly-body
inner plate-brake pedal” mounting hole,
tighten it with lock nut, and the tightening
torque of nut is 22 N·m;
2.
After aligning the booster pushrod fork to the
connecting hole of pedal arm, insert the pin
shaft, and lock it with split pin (Install the
vacuum booster with new split pin, U clamp
pin and nut);
This brake caliper is a single-cylinder one installed
on the steering knuckle with two bolts. The
hydraulic force produced by brake pedal is
converted into braking force. This braking force
equally acts on the piston and bottom of caliper
chamber to make the piston move out and brake
caliper slide in, thus an action to clamp the brake
disc is produced, which makes the brake liner affix
the brake disc, and produces a frictional force to
stop the vehicle.
Brake system 2F-16
clearance. When the piston returns, its return
stroke keeps unchanged, and the seal ring will also
return to its initial shape, so the clearance between
the brake disc and friction block will keep its
initial state unchanged.
Piston
1. Piston
2. Piston seal ring
3. Friction block
a.Clearance
Friction block
Brake disc
Note:
During the replacement of brake caliper, please
replace all the components.
Lubricate the rubber parts with clean brake fluid
for easier assembling.
Don’t apply the lubricated compressed air to avoid
the damages of rubber parts.
Once the hydraulic elements are removed or
separated, it’s required to exhaust the brake system.
The brake liner of front brake assembly must be
replaced in sets.
The tightening torque is only applicable for dry or
unlubricated fasteners.
Check of front-disc brake
Hints for brake judder repairs
The brake judder problems have the following
three features:
1.
Vibration of steering wheel: this feature is
the most obvious when it’s braked at 100 to
140 km/h {62 to 87 mph} if the steering
wheel vibrates in its rotation direction;
2.
Vibration of floor: the vehicle body shakes
forward and back, its shaking level is not
influenced by the vehicle speed;
3.
Vibration of brake pedal: an impulse force
trys to push the brake liner, and this impulse
is transmitted to the brake pedal during the
braking operation.
Repair them with clean or unpolluted wrench.
Return clearance
When the hydraulic pressure acts on the piston, the
piston moves to left. At this time, the seal ring
produces a large pressure to the piston, so it moves
with the piston. However, the part of seal ring is
fixed in the ring groove of brake caliper as shown
in the figure. When the piston moves to left, the
seal ring will be torsioned and deformed.
After the hydraulic pressure is released, the elastic
force stored in the seal ring makes the piston move
to right and return to its initial position. When the
piston moves, the brake liner will move with it,
and the clearance between brake disc and liner will
be gradually increased.
After the friction block is worn, the clearance
between the brake disc and friction block will be
increased, and the piston stroke will be also
increased. The seal ring has a certain deformation,
but after its deformation exceeds the certain value,
the seal ring will move the groove of inner end of
cylinder body, and the elastic deformation of seal
ring will have the specified limit.
After the clearance is increased, the piston is
required to move a more distance to eliminate the
The following are several main reasons to make
the brake shake:
1.
Excessive jumps of brake disc, the swing
thickness from one side to other side is
uneven:
At the place 10 mm {0.39in} away from the edge
of brake disc, if its jump exceeds 0.05mm {0.002
in}, it indicates that the uneven wears of disc are
caused by uneven contact of liner and disc. If its
jump is below 0.05mm {0.002in}, it indicates that
no uneven wears occur.
2.
Thermal deformation of disc:
Repeated violent braking operations can make the
local temperature of disc rise up to about
1,000℃{1,832ºF}, thus it will lead to the
deformation of disc.
Brake system 2F-17
3.
Due to the changes of corroded disc
thickness and friction coefficient:
If the vehicle parks in wet environment for a long
time, the friction surface of disc will be corroded,
its uneven corrosion thickness is sometimes like
corrugations, its friction coefficient will be
changed and produce a reaction force.
Procedures for check and repair
Certify
the
customer0’s
Peform the transverse jump test. (refer
to the transverse jump test)
Below 0.05mm
{0.002in}
Above 0.05mm {0.002in}
Appear
Disappear
Confirm whether the
brake shakes
Perform the thickness change
test (see below)
Below
0.05mm
{0.002in}
Confirm remove the disc, install it
in other phase position, and reperform the transverse jump test.
Whether the brake shakes
Above 0.015mm {0.0005in}
Above
0.05mm
{0.002in}
Below 0.015mm {0.0005in}
Certify the repair conditions.
Machine the disc with an onboard grinder
Tighten all the hub nuts up to the
same torque to fix the brake disc,
and measure its transverse jump.
Grind with an on-board grinder (below
0.015mm{0.0005in}).
Completion of work.
Check of transverse jump
1.
Tighten the hub nut diagonally, and ensure
the correct installation of disc and hub, or
insert the washer between the hub bolt and
hub nut.
The thickness of washer is 10mm {0.39 in} and its
inner diameter is over 12mm{0.47 in}.
Check of its thickness changes
2.
1.
Clean the friction surface of brake disc and
brake liner with a brake cleaner.
2.
Measure the thickness of each point shown in
the figure with a caliper dial indicator.
3.
Deduct the minimum value with the measured
maximum value. If the result can’t meet the
requirements, machine the brake disc with a
grinding tool.
3.
After tightening all the hub nuts up to the
same torque, place a dial indicator on the
friction surface of brake disc in the position
about 10mm{0.39in}away from the edge of
disc.
Turn the brake disc once and measure its
transverse jump.
Its jump limit: 0. 05mm{0. 002 in}.
Its thickness change limit: 0.015 mm {0.0005 in}
Warning:
• Don’t exceed the minimum thickness of brake
disc.
Brake system 2F-18
Thickness check of front or rear brake disc
1.
Front steering knuckle with brake assembly
Measure the thickness of brake disc.
Caution:
If the brake disc is removed from the vehicle for
machining, it may cause its excessive jump.
Therefore, it’s required to be machined when the
brake disc is installed on the vehicle. Minimum
thickness: front disc: 22mm {0. 87 in}. Adopt its
minimum thickness machined on the vehicle: 22. 8
{0. 90in}
2.
If the thickness of brake disc is not within the
technical requirements, replace the brake disc.
Table II: Removal of front-disc brake assembly
Warning:
1
Caliper support bolt

2
Front brake caliper assembly(left/right)
3
Front brake disc
4
Front outer friction plate
5
Front inner friction plate (left/right)
6
Steering knuckle assembly(left/right)
Don’t exceed the minimum thickness of brake disc.
Removal of frontdisc brake assembly
Check of brake liner thickness
1.
Jack up the front of vehicle, and support it
with a safety support.
2.
Remove the wheel.
3.
Check the residual thickness of liner, and
replace the sets of liners. Provided the
thickness of one side liner of left and right
wheels is equal to or below its minimum
thickness, it’s required to replace left and
right liners at the same time. Thickness of
liner: minimum value 2. 0mm { 0. 08in}.
4.
If the thickness of any side of left or right
wheel is below or equal to its minimum
thickness, replace the brake shoes from its
both sides.
1
Brake hose
2
Caliper support bolt
3
Caliper body
4
Shaft pin bolt
5
Guide pin rubber sleeve
For its removal and installation, refer to the
figure.
6
Guide pin
7
Carrying support
After installing it, step the brake pedal several
times, and turn the wheel by hands to confirm
the existence of brake drag.
8
Inner and outer friction plate assembly
9
Brake disc
Removal and installation of Front-disc
brake
1.
2.
Table I: List of supply-level parts for front steering
knuckle with brake assembly
Brake system 2F-19
Keypoints for removing the brake disc
1.
Before removing it, make the marks on the
hub bolt and brake disc for the references of
installation.
Mark
Keypoints for installing the brake disc
Wood
board
1.
Remove any rust or dust from the contact
surface of brake disc and hub.
2.
Assemble the brake disc by aligning to the
mark before removing it.
Keypoints for installing the brake liner
1.
Push the piston to bottom with SST.
2.
Install the brake liner.
Replacement of front brake liner
1.
2.
Remove it in the sequence shown in the
table.
Install it in the reverse sequence of removal.
1
Bolt
2
Inner and outer friction plates
3
Support assembly
4
Guide pin
5
Guide pin dust cover
6
brake caliper
Disassembly and assembling of front brake
caliper
1.
Disassemble it in the sequence shown in the
table.
2.
Assemble it in the reverse sequence of
removal.
1
Dustproof seal ring
2
Piston(refer
to
keypoints
disassembling P piston)
for
3
Piston seal ring (refer to keypoints for
disassembling P piston seal ring)
4
Bleed screw cover
5
Bleed screw
6
brake caliper body
Brake system 2F-20
Keypoints for disassembling the piston
Note:
 While blowing the compressed air into brake
caliper, blow it slowly to avoid the sudden jump
of piston.
Place SST inside the brake caliper, blow the
compressed air from the hole into brake caliper,
to make the piston push into the brake caliper.
Keypoints for disassembling the piston seal
ring
Take the brake caliper out of piston seal ring with
SST.
Check of rear-drum brake
Thickness check of brake shoe friction plate
1.
Remove brake drum.
2.
Check the thickness of residual friction
plates. Provided the thickness of any of left
and right friction plates is equal to below its
minimum thickness, replace left and right
brake shoes at the same time.
Thickness of friction plate
Its minimum value of 1.0 mm {0.04 in}
Check of brake drum
1.
Measure the inner diameter of brake drum.
Maximum value of inner diameter
204 mm {8. 03 in}
2.
Check the inner sides of brake drum for
unflat scratches or abnormal wears.
3.
If necessary, repair or replace the brake
drum.
4.
Check whether the contact of drum and
brake shoe is good when repairing or
replacing the brake drum.
Brake system 2F-21
Removal and installation of rear-drum
brake
1.
Components of rear-drum brake
For its removal and installation, see the
figure below.
Removal of rear-drum brake
Disassembled components of rear-drum brake
Rear-drum brake subassembly(left or
1
right)
2
Hexagon bolt
3
Spring washer
4
Bottom plate assembly(left or right)
5
Parking wheel cylinder assembly
1
Wheel nut
2
Wheel
3
Countersunk screw
4
Brake drum
6
Parking brake shoe assembly(left or
right)
5
Wheel speed sensor fixing bolt
7
Adjusting screw rod assembly
6
Oil pipe joint connected to wheel
cylinder
8
Upper tension spring
7
Brake fixing bolt
9
Pressure spring
8
Hub bearing unit
10
Clamping pin
9
Parking cable
11
Sight glass plug
10
Brake subassembly
12
Brake shoe assembly
13
Lower tension spring
After installing it, adjust its brake clearance
and apply the following work.
14
Shifting plate
(1) Step the brake pedal several times, and then
confirm no brake drag.
15
Pressure spring cap
16
Adjusting spring
(2) Check the clearance between the pedal and
floor.
17
Rear hub bearing unit
18
Brake drum
(3
19
Countersunk screw
2.
Check the stroke of parking brake handle.
Brake system 2F-22
Mark
Keypoints for removing the brake drum
Before removing the brake drum, make the marks
on the bolt and brake drum for references of
installation.
Keypoints for installing the brake drum
1.
Remove the rust and dust from the contact
surface of drum brake.
2.
Align the mark made before the removal, and
assemble the brake drum.
3.
After installing the brake drum, adjust the
clearance of brake shoe as per the following
steps.
(1) Turn the regulator on adjusting support to
make its length L: 2mm-3 mm {0.079 in 0.11in}.
(2) Remove the rust and dust from the contact
surface of drum brake.
(3) Align the mark made before the removal, and
assemble the brake drum.
(4) Step the brake pedal 30 times to activate the
automatic adjuster.
Disassembly and assembly of wheel cylinder
1
Dust cover
2
Wheel cylinder piston
3
Wheel cylinder rubber cup
4
Wheel cylinderspring
5
Bleed screw cover
6
Bleed screw
7
Wheel cylinder body
Note

In case of finding out any problem, replace the
wheel cylinder assembly.
1.
Assemble it in the sequence shown in the table.
2.
Assemble it in the reverse sequence of
removal.
Brake system 2F-23
Check of rear-disc brake
Hints for repair of brake tremor (refer to
front-disc brake)
Thickness check of rear brake disc
1.
Measure the thickness of brake disc.
Note:
If the brake disc is removed from the vehicle for
machining, it may cause its excessive jump.
Therefore, it’s required to machine during the
installation of brake disc on the vehicle.
1
Wheel nut
Minimum thickness: rear disc: 8mm {0.31in}
Adopt the minimum thickness machined on the
vehicle: 8.8 {0.35in}
2. If the thickness of brake disc is not within the
technical requirements, replace the brake disc.
Warning:

Don’t exceed the minimum thickness of
brake disc.
Thickness check of brake liner
1.
Jack up the front of vehicle with a jack, and
tie it firmly with a safety support.
2.
Remove the wheel.
3.
Check the residual thickness of liner, and
replace the liner in sets. Provided the
thickness of any block of left and right
wheels is below or equal to its minimum
thickness, it’s required to replace left and
right liners at the same time.
Minimum thickness of rear liner: 2.0 mm {0.8in}
4.
If the thickness of any side of left and right
wheels is below or equal to its minimum
thickness, replace both brake shoes in sets.
Brake system 2F-24
Removal and installation of rear-disc
brake
1
Wheel nut
2
Wheel
1.
3
Hollow bolt
4
Caliper assembly
socket bolt
5
Caliper assembly
6
Pin shaft screw
7
Guide pin
8
Guide pin dust cap
9
Carrying support
10
Inner friction plate
11
Outer friction plate
12
Countersunk screw
13
Brake disc
14
Brake mounting bolt
15
Hub bearing unit
16
Brake bottom plate
For its removal and installation, see the
table.
Table 1
Removal of
rear-disc brake
2.
Keypoints for removing the brake disc:
fixing
hexagonal
Before removing the disc, make the marks on
hub bolt and brake disc for the references of
installation.
3.
Keypoints for installing the brake disc
a.
Remove any rust or dust from the contact
surface of brake disc and hub.
b.
Align the mark made before the removal,
and assemble the brake disc.
Mark
4.
Instructions for removal of rear brake shoe:
a.
Remove it in the sequence of installation;
b.
Install it in the reverse sequence of removal.
5.
Instructions for installing rear brake shoe:
a.
Push in the piston fully with SST;
b.
Install the brake shoe.
6.
Description of caliper body disassembly
(refer to the description of front caliper
disassembly)
Brake system 2F-25
3.
Place the parking brake handle in loosened
position, loosen and remove three fixing
bolts(2) of parking brake handle, and the
tightening torque of bolt during the
assembly:18 to 26N.m.
4.
Loosen the self-lock nut of parking handle tie
rod regulator(4), and take the joint of parking
cable(5) or (6) out of regulator slot.
5.
Remove the joint of loading cable (5) or (6)
sheath from the body mounting support.
6.
Pull the parking cable jacket (7) out of body
hole.
7.
Remove the tightening bolt (10) of parking
cable fixed support(8) or (9) from the body
fixing hole.
Parking brake system
General and operation
It’s displayed through the parking brake caution
installed on the instrument panel. When
light
the ignition switch is turned on, the caution light
goes on. When the parking handle is put down, the
caution light goes out. Whenever the parking
control mechanism is pulled, when the ignition
switch is turned, the caution light should be on.
Structure diagram
Parking brake
1.
Parking brake handle
2.
Parking brake cable (right)
3.
Parking brake cable (left)
4.
Parking brake handle fixing bolt
5.
Parking brake cable fixing bolt
Repair instructions
Parking brake handle
1.
Remove the parking brake handle cover of
auxiliary instrument panel(a) (see the details
of auxiliary instrument panel removal
method).
2.
Remove the wire plug (3) of brake lamp
switch on parking handle (1).
Brake system 2F-26
The tightening torque
assembly:18 to 26N.m
of
bolt
during
the
Note:
In case of installing the fixed support(8) or (9) into
body fixing hole, fix it with a bolt after placing the
support locating fork into body locating hole.
11. Remove the parking brake cable end from the
baffle and hook of rear caliper parking
mechanism (21).
Note: the operation method specified in 11 is only
applicable for the configuration of disc brake.
8.
Loosen and remove the fixing bolt (11) of
parking cable fixed support (12) from rear
torsion beam fixing hole. Tightening torque of
bolt while assembling it:18 to 26N.m.
Note: when installing the fixed support (12) into
rear torsion beam fixing hole, tighten it with a bolt
again after placing the support locating fork into
the body locating hole.
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 5-7 teeth.
Adjustment of parking brake handle stroke
9.
After removing the brake drum (16) and
friction plate (19) of drum brake, disengage
the parking brake cable end(14) of friction
plate (19) from the parking tie rod.
10. Disengage and remove snap spring (13) of
parking brake cable end from brake bottom
plate (20) through hole to remove the parking
cable.
Note: the operation methods specified in 9,10 are
only applicable for the configuration of drum brake.
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 adjusting nut (2) on parking handle
tie rod,
Pull up the handle to check 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.
Brake system 2F-27
Parameters
General technical parameters
Item
Stroke of parking brake handle
Instructions
5 to 7 teeth[tensile force of 245N (25 kgf, 55 Ibf)]
Locking torque parameters
Item
Nm
Lb-Ft
Lb-in
Parking handle mounting nut
22
-
89
Parking cable fixed support
mounting bolt
22
-
89
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
●
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
Brake system 2F-28
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 selfcheck 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;
Brake system 2F-29
●
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
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.
3)
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 (5A)
4.
5.
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.
Check whether the bonding point of ABS earth
wire is loosened, and whether its earthed
position is changed.
Apply the seal gum to the exposed end of wire,
and adopt the shrinkable tube gland.
Brake system 2F-30
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
ABS system parts are correctly connected,
jammed or slashed.

The wires shall be arranged near to highvoltage 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.
Ignition
coil/ignition
wire/spark plug
Gear ring
Generator
Wheel speed sensor
Hydroplaning
Hydroplanin
Water
line
Don’t cling
.
Brake system 2F-31
Introduction of ABS 9 system
I.
Composition of ABS 9 system
As shown in the figure below, ABS 9 consists of hydraulic module with an electronic control unit and
wheel speed sensor .
① Wheel speed sensor
② ABS hydraulic control module of electronic control unit
Note: this drawing is only for reference. For the detailed positions of elements, please refer to the vehicle
maintenance manual.
II. Hydraulic diagram for Haima M3 ABS 9 X-type arrangement
The brake system is arranged in X shape. As shown in the figure below, ABS 9 hydraulic regulator
includes a motor, two return pumps, two energy accumulators and eight solenoid valves.
Brake system 2F-32
The following meanings of English abbreviations in Fig.:
M
First circuit of brake master cylinder
RR
Right rear wheel
M
Second circuit of brake master cylinder
FLEV
left front wheel oil inlet valve
M
motor
FLAV
left front wheel oil outlet valve
R
return pump 1
FREV
right front wheel oil inlet valve
R
return pump 2
FRAV
right front wheel oil outlet valve
A
Energy accumulator 1
RLEV
Left rear wheel oil inlet valve
A
Energy accumulator 2
RLAV
Left rear wheel oil outlet valve
F
left front wheel
RREV
Right rear wheel oil inlet valve
F
right front wheel
RRAV
Right rear wheel oil outlet valve
R
Left rear wheel
Brake system 2F-33
III. Haima M3 ABS 9 ECU interface circuit
3.1 Haima M3 circuit diagram
Brake system 2F-34
3.2 Definitions of Haima M3 pins
Pin
Function
Pin
Function
1
Motor power terminal(positive)
20
Undefined
2
Wheel speed output(right front)
21
Undefined
3
EBD warning lamp
22
Undefined
4
wheel speed sensor signal terminal(right
front)
23
Undefined
24
Undefined
25
Power end of valve relay
26
CAN H (unused)
27
ABS warning lamp
28
ECU power terminal (ignition power line)
29
wheel speed sensor signal terminal (right
rear)
30
brake lamp switch
31
wheel speed sensor power terminal (left
rear)
5
Undefined
6
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
32
Undefined
14
CAN L (unused)
33
Speed output
15
Undefined
34
Undefined
16
wheel speed sensor power terminal (right
front)
35
Undefined
36
Undefined
17
wheel speed sensor power terminal (right
rear)
37
Undefined
18
wheel speed sensor signal terminal (left
rear)
38
ECU ground terminal
19
wheel speed sensor power terminal (left
front)
Brake system 2F-35
Fault diagnosis
I.
Diagnostic flow
1
The vehicle enters into the repair factory.
2
Analysis of customers’ problems
3
Reading of fault codes
Faults
Go to Step 4
No faults
Go to Step 6
4
Record the fault codes, and then remove the fault codes.
5
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.
6
For the faults without fault codes, repair and go to Step 9.
7
Remove the faults as per the list of fault codes, and then go to Step 9.
8
Remove the faults as per the list of fault symptoms, and then go to Step 9.
9
Confirm the removal of faults, perform the repair and test on completion.
10
Avoid the regeneration of faults.
Conclusion
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.
Brake system 2F-37
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
1. Shake ABS ECU connector lightly
up, down, left or right.
1
When the vibration
may be a major
cause
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.
2
When
the
temperature may be
a major cause
3
When the excessive
electricity load 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.
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.
Remarks
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
opencircuited/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.
Brake system 2F-38
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
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
Brake system 2F-39
DTC fault code
Description of fault codes
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.
Brake system 2F-40
Diagnostic steps
Step
Operation
Yes
No
1
Is the initial check performed?
Perform Step 2.
Perform the initial
check. (see Page 3)
2
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.
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.
-
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
No
1
Cool the vehicle for 5 minutes, and check whether its
faults are removed?
-
Perform Step 2.
2
Is the initial check performed?
Perform Step 3.
Perform the initial
check.
3
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.
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.
-
Brake system 2F-41
Step
Operation
Yes
No
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
4.4 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
No
1
Cool the vehicle for 5 minutes, and check whether its
faults are removed?
-
Perform Step 2.
2
Is the initial check performed?
Perform Step 3.
Perform the
initial check.
3
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.
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.
-
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.
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
No
1
Is the initial check performed?
Perform Step 2.
Perform the
initial check.
2
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.
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.
-
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:
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
No
1
Is the initial check performed?
Perform Step 2.
Perform the initial
check.
2
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.
-
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
No
1
Is the initial check performed?
Perform Step 2.
Perform the
initial check.
2
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
3
4
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 highpressure 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).
A
B
C
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.
Brake system 2F-45
If not successful, exhaust it again at each wheel.
D
E
Check the level of brake fluid, and ensure that it’s between the maximum and minimum
values.
4.2 Manual pedal exhaustion
A
B
C
D
E
F
G
H
J
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
A
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.
B
B1
C
D
E
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
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
48
Number of rear shaft gear ring teeth
40
Tire model
185/60 R15
Spare tire model
The same as model of tire
Repair manual for Haima NA01 ESP 9

Customer:
Haima
Vehicle type:
M3
Product system:
ESP 9
Types of brake circuit arrangements:
Arrangement of X circuit
Drive type:
Front wheel drive
Diagnostic specifications:
KWP2000
Communication type:
CAN
In the whole exhaustion, the level of brake fluid in fluid reservoir can’t be below its lowest mark.
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 selfcheck 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.
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.
6.
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.
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.
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
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 highvoltage 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.
Hydroplaning
Hydroplaning
Water line
Don’t cling.
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.
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.
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
M
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
A1
Energy accumulator 1
RREV
Right rear wheel inlet valve
A2
Energy accumulator 2
RRAV
Right rear wheel outlet valve
FL
Left front wheel
HSV1
High-pressure valve 1
FR
Right front wheel
HSV2
High-pressure valve 2
RL
Left rear wheel
USV1
Guide valve 1
RR
Right rear wheel
USV2
Guide valve 2
FLEV
Left front wheel inlet valve
P/U
Pressure gauge
Brake system 2F-53
III. Haima M3 ESP 9 ECU interface circuit
ECU circuit diagram
Brake system 2F-54
Definitions of ECU pins
Pin
Function
Pin
Function
1
Motor power terminal(positive pole)
20
Undefined
2
Wheel speed sensor output(unused)
21
Undefined
3
EBD warning lamp
4
Wheel
speed
sensor
terminal(right front)
22
Undefined
23
ESP OFF indicator lamp
5
Undefined
24
Undefined
6
Diagnostic k line(unused)
25
Valve relay power terminal
7
Undefined
26
CAN1h (CAN1 high)
8
Wheel speed sensor signal terminal (left
front)
27
Undefined
28
ECU power terminal(ignition power line)
9
Undefined
29
10
Speed output
Wheel speed sensor signal terminal(right
rear)
11
Undefined
30
Brake lamp switch
12
ESP OFF switch
31
13
motor ground end
Wheel speed sensor power terminal(left
rear)
14
CAN1 l (CAN1 low)
32
Undefined
15
Undefined
33
ABS warning lamp
16
Wheel
speed
sensor
terminal(right front)
power
34
ESP multi-functionindicator lamp
35
Undefined
17
Wheel
speed
terminal(right rear)
power
36
Undefined
37
Undefined
38
ECU ground end
sensor
signal
18
Wheel speed sensor signal terminal(left
rear)
19
Wheel speed sensor power terminal(left
front)
Brake system 2F-55
Fault diagnosis
I.
Diagnostic flow
1
The vehicle enters into the repair factory.
2
Analysis of customers’ problems
3
Reading of fault codes
Faults
Go to Step 4
No faults
Go to Step 6
4
Record the fault codes, and then remove the fault codes.
5
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
6
For the faults without fault codes, repair and go to Step 9.
7
Remove the faults as per the list of fault codes, and then go to Step 9.
8
For the occassional fault, repair and then go to Step 9.
9
Confirm the removal of faults.
10
Avoid the regeneration of faults.
Conclusion
Brake system 2F-56
II. For the faults without fault codes, repair it.
If the faults occur to the brake system, but ESP 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 ESP 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 overlong stroke of brake pedal)

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 ESP performances, whipping and long
braking distance,etc. For the correct installation methods, please refer to the marks near to oil holes in
ESP 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 ESP will lead to the constant illumination of ABS and ESP warning
lamps, 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.
S/N
Possible causes
of faults
Simulated faults
● Shake ESP ECU connector lightly
up, down, left or right.
1
When
the
vibration may be
a major cause
● Shake ESP wire lightly up, down,
left or right.
● Shake the sensor lightly up, down,
left or right.
● Shake other moving parts(e.g. wheel
bearing) lightly.
2
3
When
the
temperature may
be a major cause
When
the
excessive
electricity
load
may be a major
● Heat the parts with possible faults
with an air blower.
● Check them for cold welding with
cold spraying agent.
● Turn on all the switches of electric
appliances, including the lamp and
wiper, to make the power supply of
vehicle work at high load.
Remarks
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
opencircuited/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.
Brake system 2F-57
cause
If no faults is regenerated at this time, it must be diagnosed and repaired until the regeneration of faults.
Generally speaking, the occasional accident will become gradually a regenerable fault, and can’t disappear
automatically.
IV. Analysis of fault codes
4.1 List of fault codes
DTC
DTC(Hex)
DTC Description
C190004
0x590004
High voltage of ECU
C190104
0x590104
Low voltage of ECU
C100004
0x500004
ECU fault(hardware, fault of controller)
C101008
0x501008
ECU fault(software error)
C006B06
0x406B06
Abnormal ABS/ESP control(overlong continual action time, etc)
C003108
0x403108
Faults of left front wheel speed sensor signals: off-limit, loss, noises,
intermittent interruptions
C003200
0x403200
Open circuit of left front wheel speed sensor
C00A000
0x40A000
left front wheel speed sensor shorted to ground
C00A100
0x40A100
left front wheel speed sensor shorted to power supply
C00A900
0x40A900
Unknown fault of left front wheel speed sensor (its fault causes can’t be
definitely known)
C003408
0x403408
Error of right front wheel speed sensor signal: off-limit, loss, noises,
interruptions
C003500
0x403500
Open circuit of right front wheel speed sensor
C00A200
0x40A200
right front wheel speed sensor shorted to ground
C00A300
0x40A300
right front wheel speed sensor shorted to power supply
C00AA00
0x40AA00
Unknown fault of right front wheel speed sensor (its fault causes can’t be
definitely known)
C003708
0x403708
Error of left rear wheel speed sensor signal: off-limit, loss, noises,
interruptions
C003800
0x403800
Open circuit of left rear wheel speed sensor
C00A400
0x40A400
Left rear wheel speed sensor shorted to ground
C00A500
0x40A500
Left rear wheel speed sensor shorted to the power supply
C00AB00
0x40AB00
Unknown fault of left rear wheel speed sensor (its fault causes can’t be
definitely known)
C003A08
0x403A08
Error of right rear wheel speed sensor signal: off-limit, loss, noises,
interruptions
C003B00
0x403B00
Open circuit of right rear wheel speed sensor
C00A600
0x40A600
Right rear wheel speed sensor shorted to ground
C00A700
0x40A700
Right rear wheel speed sensor shorted to the power supply
C00AC00
0x40AC00
Unknown fault of right rear wheel speed sensor (its fault causes can’t be
definitely known)
C109904
0x509904
Regular faults of wheel speed sensor (interchange of sensors, faults of several
sensors, etc)
Brake system 2F-58
DTC
DTC(Hex)
DTC Description
C004460
0x404460
Fault of pressure gauge (signal)
C004510
0x404510
Fault of pressure gauge (wire)
C004008
0x404008
Fault of brake lamp switch reliability
U160108
0xD60108
Failure of brake lamp switch CAN signal
C006108
0x406108
Error of lateral acceleration sensor signal
C006208
0x406208
Error of vertical acceleration sensor signal
C006308
0x406308
Error of yaw velocity sensor signal
C019604
0x419604
Fault of yaw velocity sensor
C00A800
0x40A800
Non-calibration or calibration failure of yaw velocity sensor
U000500
0xC00500
Overhigh voltage of CAN bus
U000700
0xC00700
Overlow voltage of CAN bus
C100104
0x500104
Fault of CAN bus hardware
U000104
0xC00104
OFF fault of CAN bus
U100104
0xD00104
Error of external CAN bus
U010004
0xC10004
EMS CAN report overtime
U010008
0xC10008
Interruption of EMS data or signal failure
C106600
0x506600
Calibration error of SAS steering wheel angle sensor
C046008
0x446008
Fault of SAS steering angle angle sensor (signal)
U012604
0xC12604
SAS steering angle angle sensor CAN report overtime
U012608
0xC12608
SAS steering angle angle sensor data interruption or signal failure
U010104
0xC10104
TCU CAN report overtime
U010108
0xC10108
TCU data interruption or signal failure
C001004
0x401004
Valve fault, left front inlet valve
C001104
0x401104
Valve fault, left front outlet valve
C001404
0x401404
Valve fault, right front inlet valve
C001504
0x401504
Valve fault, right front outlet valve
C001804
0x401804
Valve fault, left rear inlet valve
C001904
0x401904
Valve fault, left rear outlet valve
C001C04
0x401C04
Valve fault, right rear inlet valve
C001D04
0x401D04
Valve fault, right rear outlet valve
C000104
0x400104
Valve fault, guide valve１
C000204
0x400204
Valve fault, guide valve２
C000304
0x400304
Valve fault, high-pressure valve１
C000404
0x400404
Valve fault, high-pressure valve２
C109504
0x509504
Fault of valve relay
C002004
0x402004
Fault of return pump
C007208
0x407208
Common fault of valve (valve overheat protection, signal failure, hardware
fault)
Brake system 2F-59
DTC
DTC(Hex)
DTC Description
C104C04
0x504C04
Fault of ESP OFF switch
C121208
0x521208
Error of configuration code
U160208
0xD60208
Failure of hand brake signal (CAN signal)
C100300
0x500300
Fault of clutch switch
U160308
0xD60308
Failure of clutch signal (CAN signal)
U160408
0xD60408
Failure of reverse gear switch signal (CAN signal)
C108C08
0x508C08
Constant high/low level of reverse gear switch signal
4.2 C190004; C190104 ECU supply fault
Possible fault causes
(1) Overhigh or overlow voltage of battery;
(2) Poor grounding of body.
Repair and diagnostic methods
(1) Measure the voltage of battery, and charge the
battery if necessary (standard voltage of 9. 3V
to 16. 8V);
(2) Check two ground points of ESP, including
ground point of ESP electronic control unit
and ground point of return pump motor;
(3) Start all the high-power electric appliances on
the vehicle, and measure the supply voltage of
ESP, because its power supply may be
insufficient at high electricity load;
(4) Measure the voltage fluctuation produced by
turning on or off the high-power electric
appliance during the start of vehicle. Any
potential fault of electrical appliance may lead
to the substantial voltage fluctuation of supply
circuit.
4.3 C100004 ECU fault
(1) Read the data flow of wheel speed sensor
with a diagnostic unit, and observe whether
any wheel speed is constantly overhigh or
overlow;
(2) Start to test the vehicle in figure eight
inclination, turn the steering angle fully to left
or right during the test, and read the fault code
again;
(3) If no faults related to steering angle angle
sensor or yaw velocity sensor occur, it’s
required to check whether the installation
position of ESP is horizontal and tight. ESP
support can’t be applied for installing any
other device.
4.5 C003200; C00A000; C00A100; C003500;
C00A200;
C00A300;
C003800;
C00A400;C00A500; C003B00; C00A600;
C00A700 wheel speed sensor circuit faults
Possible fault causes
(1) Disconnection, loosened connection
fracture of wheel speed sensor wires.
or
(2) Reverse connection of wheel speed sensor
signal line and power line.
(3) Short circuit of signal line to ground.
Possible fault causes
Damages of ECU.
Repair and diagnostic methods
Repair and diagnostic methods
(1) Check whether any wheel speed sensor wire
is opened or shorted;
(1) Replace ESP assembly, and exhaust the brake
pipe.
(2) Check whether any wheel speed sensor wire
connector is loosened or broken;
4.4 C006B06 abnormality of brake system
(overlong action time of ABS/ESP)
(3) Check whether the power line and signal line
of wheel speed sensor are reversely connected;
Possible fault causes
(4) Increase the speed of vehicle up to 40km/h to
perform the dynamic self-check of ESP
system;
(1) Continual violent driving or
continual application of brake;
long-time
(2) Incorrect signals of wheel speed sensor;
(3) Abnormal signals of steering angle angle
sensor and yaw velocity sensor.
Repair and diagnostic methods
(5) If the fault can’t be still removed after
finishing its dynamic self-check, replace the
wheel speed sensor.
4.6 C003108; C00A900; C003408; C00AA00;
Brake system 2F-60
C003708; C00AB00; C003A08; C00AC00;
C109904 wheel speed sensor signal fault
Possible fault causes
(1) Fault of brake lamp switch or its circuit;
Possible fault causes
(2) Fault of pressure gauge.
(1) The wheel speed sensor wire is bent, and its
connector is loosened or broken;
Repair and diagnostic methods
(2) The wheel speed sensor signal line is shorted
to the power supply;
(3) The wheel speed sensor power line 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).
(1) Check whether the brake lamp switch and its
circuit are normal;
(2) Replace ESP assembly, and exhaust the brake
pipe.
4.8 C004008; U160108 fault of brake lamp
switch (BLS)
Possible fault causes
(1) Open circuit or short circuit of brake lamp
switch wire;
(2) Wrong installation of brake lamp switch;
(3) Damages of brake lamp switch.
Repair and diagnostic methods
(7) Faults of wheel speed sensor body.
(1) Check the brake lamp switch and its wire;
(8) Wrong number of gear ring teeth.
(2) Replace the brake lamp switch.
(9) Above-normed size of tire.
4.9 C006108; C006208; C006308; C019604;
C00A800 Faults of yaw velocity sensor
Repair and diagnostic methods
(1) Check whether the wire of wheel speed sensor
is bent;
The yaw velocity sensor includes three signals of
lateral acceleration, vertical acceleration and yaw
velocity.
(2) Check whether each connector of wheel speed
sensor wire is loosened or broken;
Possible fault causes
(3) Check whether the wire of wheel speed sensor
is shorted to power supply or ground;
(4) Check whether the wheel speed sensor is
correctly fixed;
(5) Read the data flow of wheel speed sensor
with a diagnostic unit, record whether each
wheel speed is consistent with its acceleration
speed during the travel of vehicle, and
whether the shown vehicle speed is correct;
(6) If the inconsistency of shown wheel speeds
occurs, and check the gear ring of
corresponding wheel speed sensor signal for
lost teeth, dirts or strange substances,
demagnetizing or eccentricity;
(7) After repairing the wheel speed sensor, it’s
required to increase the speed of vehicle up to
at least 40km/h for dynamic self-check of
ESP system;
(8) If the fault can’t be still removed after
finishing its dynamic self-check, replace the
wheel speed sensor.
4.7 C004460; C004510 pressure gauge fault
(1) Incorrect installation position of yaw velocity
sensor; (be sure to ensure that the sensor
keeps in horizontal position on the vehicle
body);
(2) Incorrect calibration of yaw velocity sensor;
(3) Damages of yaw velocity sensor.
Repair and diagnostic methods
(1) Adjust the installation position of yaw
velocity sensor, and check whether its fixing
position is bent or worn;
(2) Re-calibrate the yaw velocity sensor;
(3) Replace the yaw velocity sensor.
4.10 U000500; U000700; C100104; U000104;
U100104 CAN bus faults
Possible fault causes
(1) Overhigh or overlow voltage of battery
(standard voltage of 9. 3V to 16. 8V);
(2) Faults of CAN bus network;
(3) Damages of ECU.
Brake system 2F-61
Repair and diagnostic methods
(1) Measure the voltage of battery, and charge it
if necessary;
(2) Check CAN bus and each of its nodes;
(3) Replace ESP assembly, and exhaust the brake
pipe.
4.11 C106600; C046008; U012604; U012608
Faults of steering angle sensor
Possible fault causes
(1) Incorrect calibration of steering angle sensor;
(2) Steering angle sensor circuit fault;
C001804; C001904; C001C04; C001D04;
C000104; C000204; C000304; C000404;
C007208 Faults of solenoid valve
Possible fault causes
(1) Overheat protection of system;
(2) Damages of ESP electronic control unit.
Repair and diagnostic methods
(1) After cooling the vehicle for 10min, read the
fault codes again;
(2) Replace ESP assembly, and exhaust the brake
pipes.
(3) Loosening or breakage of steering angle
sensor plug;
4.14 C109504 fault of solenoid valve relay
(4) Damages of steering angle sensor.
(1) Poor power supply of solenoid valve(low
supply voltage, damages or poor contact of
fuse);
Repair and diagnostic methods
(1) Cancel the calibration of steering angle sensor,
and re-calibrate it;
(2) Check the wires of steering angle sensor;
(3) Check and re-insert the steering angle sensor
plug;
(4) Replace the steering angle sensor.
4.12 U012604; U012608; U010104; U010108
Faults of CAN bus nodes
Possible fault causes
(1) Interruption of CAN bus communication;
(2) Poor power supply of CAN bus nodes;
(3) Faults of CAN bus nodes(disengaged from
CAN bus or ECU fault).
Repair and diagnostic methods
(1) Check whether CAN bus communication is
normal;
(2) Turn off the ignition switch, measure the
resistance from each CAN bus node to ESP of
CAN-H and CAN-L lines;(standard value:
below 5Ω;)
(3) Measure the resistance between CAN-H and
CAN-L lines from the connector of each CAN
node (keep the connection of plug); (standard
value: 60Ω);
(4) Check the power supply of each CAN bus
node;
(5) Read the fault codes of each node of CAN bus,
and carry out the corresponding check as per
the fault codes.
4.13 C001004; C001104; C001404; C001504;
Possible fault causes
(2) Poor grounding of ESP electronic control unit;
(3) Damages of ESP electronic control unit.
Repair and diagnostic methods
(1) Check the supply wire of valve relay, fuse and
power voltage;
(2) Adopt a 21W test lamp to measure the voltage
drop between ESP connector valve relay
power pin and battery positive pole; (standard
value: below 0.2V);
(3) Adopt a 21W test lamp to measure the voltage
drop between ESP connector ESP ECU
ground pin and body ground point; (standard
value: below 0.2V);
(4) Increase the speed of vehicle up to at least
40km/h for dynamic self-check of ESP
system;
(5) If the fault can’t be still removed after
finishing its dynamic self-check, replace ESP
assembly, and exhaust the brake pipe.
4.15 C002004 return pump motor fault
Possible fault causes
(1) Overheat protection of system;
(2) Poor power supply of pump motor(low supply
voltage, damages of fuse or poor contact);
(3) Poor grounding of pump motor;
(4) Damages of pump motor.
Repair and diagnostic methods
(2) After cooling it for 10 min, read the fault
codes again;
Brake system 2F-62
(3) Check the power line of pump motor, fuse
and power voltage;
(4) Adopt a 21W test lamp to measure the voltage
drop between ESP connector pump motor
power pin and battery positive pole; (standard
value: below 0.2V);
(5) Adopt a 21W test lamp to measure the voltage
drop between ESP connector pump motor
ground pin and body ground point; (standard
value: below 0.2V);
(1) Check the hand brake signal line;
(2) Check the clutch switch;
(3) Check the clutch signal line;
(4) Check the reverse gear signal line.
Removal and installation
I.
Steps for removing ESP assembly
1.
Make the ignition switch in OFF position, and
disconnect the negative pole of battery.
2.
Remove the wire from ESP 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 ESP assembly and oil hole of brake pipe to
avoid the entry of impurities.
(1) ESP OFF switch is pressed by the articles;
5.
Take down ESP from the fixed support.
(2) Damages of ESP OFF switch or its circuit.
II. Installation steps of ESP assembly
Repair and diagnostic methods
1.
(1) Turn off ESP OFF switch manually, and
restart ESP functions;
Install ESP assembly on the support,and
tighten it up to the torque of 8±2Nm.
2.
Take down the plugs from ESP thread hole
and brake pipe, connect the brake pipe into
ESP 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.
4.
After replacing ESP assembly, be sure to
write in its configuration information(if any).
5.
After replacing ESP assembly, be sure to
calibrate the steering angle sensor and yaw
velocity.
(6) Increase the speed of vehicle up to at least
40km/h for dynamic self-check of ESP
system;
(7) If the fault can’t be still removed after
finishing its dynamic self-check, replace ESP
assembly, and exhaust the brake pipe.
4.16 CC104C04 ESP OFF switch fault
Possible fault causes
(2) Check ESP OFF switch.
4.17 C121208 ESP Errors of configuration
information
Possible fault causes
(1) No configuration information is written in;
(2) Non-matching of configuration information.
Repair and diagnostic methods
Write in the correct configuration information with
a diagnostic unit.
III. Exhaust instructions
●
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 ESP 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.
(5) Abnormality of reverse gear signals;
●
(6) Open circuit or short circuit of reverse gear
signal line;
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.
4.18 U160208; C100300; U160308; U160408;
C108C08
Abnormality
of
hand
brake/clutch/reverse gear signals
Possible fault causes
(1) Abnormality of hand brake signals;
(2) Faults of clutch switch;
(3) Abnormality of clutch signals;
(4) Open circuit or short circuit of clutch signal
line;
Repair and diagnostic methods
Brake system 2F-63
3.1 Exhaust with an exhaustion/filling unit (exhaust pressure of 2 bar).
A
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
B
Check the stroke of pedal.
C
If not successful, exhaust it again at each wheel.
D
E
Check the level of brake fluid, and ensure that it’s between the maximum and minimum values.
3.2 Manual pedal exhaustion
A
B
C
D
E
F
G
H
J
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.
Brake system 2F-64
3.3 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.
A
Open the bleed screw on the wheel cylinder, until all the air bubbles are drained.
Sequence: left rear, left front, right front, right rear
B
Repeat stepping the pedal back and forth.
B1
Check the stroke of pedal.
C
If not successful, exhaust it again at each wheel.
D
E
Check the level of brake fluid, and ensure that it’s between the maximum and minimum 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.
●
In case of repeating a phase or whole exhaustion, be sure to wait for 5min, so as to make the solenoid
valve cooled, otherwise the solenoid valve may be damaged due to overheat.
IV. Instructions for calibrating the integrated inertial sensor (ESP9i system)
ESP9i system integrates the yaw velocity sensor, so it has high-level precision requirements for
installation.Its installation tolerance must be below ±5° during the replacement, otherwise it can’t be
calibrated.
Calibration of integrated inertial sensor
Operator
Test bench/test device
Turn the steering angle directly in front, and make
the vehicle in straight travel position on the test
device.
Offset calibration for integrated inertial sensor
Preconditions for offset calibration of sensor
• The maximum inclination angle must be within the allowable range (it must be met in two alignment
directions, and refer to the figure below for details).
• The test bench must be static.
• Turn the steering angle directly in front.
• Correct tire pressure
• Normal loading conditions
• Allowed for low capacity of vehicle oil tank
• The vehicle is supported by its self wheels.
• Only one driver must be seated inside the vehicle.
• Any additional interference, e.g.door closing or engine cover closing, is not allowed.
Brake system 2F-65
• The calibration can be performed on the hub tester or flat area.
Remarks
EEPROM of delivered ESP has stored the preset offset values. During the calibration, ECU will write
the measured new data into EEPROM, and deliver them for the use of ESP. ESP can’t confirm the
above-mentioned preconditions, so the customer must ensure the validity of above calibration conditions.
If its offset value is too high, the system will reject its calibration, and the vehicle must be repaired at this
time. IIS calibration must be performed during the replacement of ESP9i.
Side view of vehicle (IIS calibration)
Please note the maximum
allowable inclination angle
during IIS calibration!
0.57°(1%)
Side view of vehicle (IIS calibration)
Please note the maximum
allowable inclination angle
during IIS calibration!
0.57°(1%)
Technical parameters for repair
Vehicle type
NA01
DOT4
Models of brake fluid
DOT4+
Super DOT4+
DOT5
Number of front shaft gear ring teeth
48
Number of rear shaft gear ring teeth
40
Tire model
195/55 R15

The site costs me over $1,000 per month keep online and is totally reliant
on donations to keep it going. Donations are totally optional,
if you can’t afford a few dollars right now please don’t feel pressured,
but if you can… Pretty please could you help?

or… get all our Haima 2 manuals for $15