Haima M3. Chassis System. Service Manual

Brake system 2F-24

Removal and installation of rear-disc
brake

1. For its removal and installation, see the

table.

Table 1

2. Keypoints for removing the brake disc:

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.

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.

1 Wheel

nut

2 Wheel
3 Hollow

bolt

4 Caliper assembly fixing hexagonal

socket bolt

5 Caliper

assembly

Pin shaft screw

7 Guide

Guide pin dust cap

9 Carrying

support

Inner friction plate

Outer friction plate

Countersunk screw

Brake disc

Brake mounting bolt

Hub bearing unit

Brake bottom plate

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)

Removal of

rear-disc brake

Mark

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Brake system 2F-25

Parking brake system

General and operation

It’s displayed through the parking brake caution
light

installed on the instrument panel. When

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).

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.

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Brake system 2F-26

The tightening torque of bolt during the
assembly:18 to 26N.m

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.

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.

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.

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.

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

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.

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Brake system 2F-27

Parameters

General technical parameters

Item Instructions

Stroke of parking brake handle 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

Parking cable fixed support

mounting bolt

22 -

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

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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 self-

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

● While the vehicle is driving, the warning lamp

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

5. The following points need to be attentioned

while connecting ABS sensor wires:

● Before pulling ABS wire and sensor wire, be

sure to disconnect the ignition switch.

● Ensure the drying and cleanness of connector,

and avoid the entry of any strange substance .

●

The connectors of ABS wires must be installed
in position in horizontal and vertical directions
to avoid their damages.

6. While connecting ABS brake pipes, be sure to

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

● MC1: connect the brake master cylinder brake

pipe 1;

● MC2: connect the brake master cylinder brake

pipe 2;

● FL: connect the brake pipe of left front wheel

brake wheel cylinder;

●

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

● RL: connect the brake pipe of left rear wheel

brake wheel cylinder;

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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. Check the voltage of battery, and check

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

5. Check whether the bonding point of ABS earth

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

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

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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 high-

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

 ABS parts are very sensitive for

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

8. ABS is an active safety system. Its main

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

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

caused by the following cases:

 Loosened fixation of ABS assembly and

ABS support.

 Loosened fixation of ABS support and

vehicle body.



Loss or damages of plastic washers on ABS
support.

Ignition

coil/ignition

wire/spark plug

Gear ring

Generator

Wheel speed sensor

Hydroplaning

Water

line

Don’t cling

Hydroplanin

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Brake system 2F-32

The following meanings of English abbreviations in Fig.:

First circuit of brake master cylinder

Right rear wheel

Second circuit of brake master cylinder

FLEV

left front wheel oil inlet valve

motor

FLAV

left front wheel oil outlet valve

return pump 1

FREV

right front wheel oil inlet valve

return pump 2

FRAV

right front wheel oil outlet valve

Energy accumulator 1

RLEV

Left rear wheel oil inlet valve

Energy accumulator 2

RLAV

Left rear wheel oil outlet valve

left front wheel

RREV

Right rear wheel oil inlet valve

right front wheel

RRAV

Right rear wheel oil outlet valve

Left rear wheel

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Brake system 2F-34

3.2 Definitions of Haima M3 pins

Pin Function

Motor power terminal(positive)

Wheel speed output(right front)

3 EBD

warning

lamp

4 wheel speed sensor signal terminal(right

front)

5 Undefined

Diagnostic K line

7 Undefined

8 wheel speed sensor signal terminal(left

front)

9 Undefined

10 Undefined

11 Undefined

12 Undefined

13 Motor

ground

terminal

14 CAN L (unused)

15 Undefined

16 wheel speed sensor power terminal (right

front)

17 wheel speed sensor power terminal (right

rear)

18 wheel speed sensor signal terminal (left

rear)

19 wheel speed sensor power terminal (left

front)

Function

Undefined

Power end of valve relay

CAN H (unused)

ABS warning lamp

ECU power terminal (ignition power line)

wheel speed sensor signal terminal (right
rear)

brake lamp switch

wheel speed sensor power terminal (left
rear)

Undefined

Speed output

Undefined

ECU ground terminal

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Brake system 2F-35

Fault diagnosis

I. Diagnostic

flow

The vehicle enters into the repair factory.

Analysis of customers’ problems

Reading of fault codes

Faults

Go to Step 4

No faults

Go to Step 6

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

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

Faults

Current fault code. Go
to Step 9.

No faults

Historical fault code.
Go to Step 9.

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

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

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

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

Avoid the regeneration of faults.

Conclusion

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Brake system 2F-36

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

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

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

serious failure of brake)

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

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

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

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

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

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

even still brake failure seriously)

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

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

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

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

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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

Remarks

When the vibration
may be a major
cause

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

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

When the
temperature may be
a major cause

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

When the excessive
electricity load may
be a major cause

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

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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

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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.

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Haima M3. Chassis System. Service Manual - part 6