Haima S5 1.5T. Service Manual - part 7

 

Fuel System 1C-13 

 

 

 

 

3.2 Demolition Fuel quantity sensor 

 

 

3.3 Demolition pump plug 

 

 

3.4

 

Demolition of the fuel hose fixed 

widget 

Remove the bracket 
spring, pull out the 
fuel pump gland.

 

Use a screwdriver or a 

special tool to open 

end of the buckle. 

Demolition ends 

snap. 

Demolition pressure 

relief valve. 

Inwards, and 

then pull up. 

Inwards, and 

then pull up. 

 

Fuel System 1C-14 

 

 

 

3.5 Demolition fuel pump at the bottom 
case.

 

 

3.6 Demolition prefilter, pump core, fine 
filter.

 

 

 

 

 

Note:

 

1. the fuel filter assembly refers to the fine filter,    
fine filter assembly UMC's part number F 01R 
02S9B6. I only fuel pump assembly part number 
for SA12-13-35Z. 

2. the use of fine filter fuel pump assembly time of 
2 years or 20,000 kilometers.

 

Use a screwdriver to 

open the plug-in. 

Remove the pump 

core and fine filter. 

Bottom snaps open. 

Bottom snaps open. 

Fuel pump prefilter. 

Fuel pump core

 

Fuel pump fine filter 

After all the components apart.. 

 

Intake and Exhaust System 

1D-1 

 

Chapter 4  Intake and Exhaust System   

Table of Contents 

 

1. Intake system ······························································································1D-2 

    1.1 Intake System Dismantling/Mounting ·····························································1D-2 

2. Exhaust System····························································································1D-3 

    2.1 Inspection of Exhaust System ·····································································1D-3 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Intake and Exhaust System 

1D-2 

 

1. Intake system 

1.1 Intake System Dismantling/Mounting 

Warning 

  When the engine and intake system stay at high 

temperature, they can easily lead to personnel 
injury. Before mounting or dismantling the intake 
system, operation shall not be conducted until the 
engine has stopped and cooled down.   

  Fuel vapor is dangerous and combustible, which 

may lead to serious injury and damage. Due to this, 
avoid spark or naked flame at the place where there 
is fuel.   

  Fuel overflow or leakage is dangerous, which may 

lead to personnel injury and property loss. In 
addition, the fuel can irritate the skin and eye. Due 
to this, Oil Circuit Safety Procedure shall be 
always observed during the operation process.   

1.  Disconnect the accumulator’s negative cable.   

2.  Dismantle parts according to the sequence 

illustrated in the table.   

3.  Mount parts according to the sequence reverse to 

the dismantling process.   

 

 

1 

Intake duct 

7 

Intake hose bracket 

2 

Intake hose 

8 

Intercooler intake hose 

3 Muffler 

tubes 

9 Intercooler outlet hose 

4 

Air flow sensor 

10 

Intercooler assembly 

5 

O-ring 

11 

Turbocharger outlet rigid pipe 

6 

Air filter 

12 

Turbocharger outlet hose 

 

Intake and Exhaust System 

1D-3 

 

2. Exhaust System   

2.1 Inspection of Exhaust System   

1.  Start the engine, and inspect if the exhaust 

pipeline suffers air leakage (If there is air 
leakage, overhaul the exhaust pipeline, or 
replace it if necessary).   

Exhaust System Dismantling/Mounting 

Warning 

  When the engine and exhaust system have yet to 

cool down, they may scald the skin. Due to this, 
dismantling work shall not be started until the 
engine has stopped and cooled down.   

1.  Loosen the accumulator’s negative cable.   

2.  Dismantle parts according to the sequence 

illustrated in the figure.   

3.  Mount parts according to sequence reverse to the 

dismantling process.   

 

1 

Front oxygen sensor 

2 

Front three-way catalyst converter 

3 Front 

hanging 

bracket 

4 

Rear three-way catalyst converter 

5 

Rear oxygen sensor 

6 

Front muffler assembly 

 

Cooling System

 1E-1 

 

Chapter 5    Cooling System   

Table of Contents 

 

1. Cooling System ··························································································1E-2 

  1.1 Engine Coolant ·························································································1E-2 
   1.1.1  Inspection of Engine Coolant’s Liquid Level·············································· 1E-2 
   1.1.2  Replace Engine Coolant ······································································ 1E-2 
 1.2  Vice radiator cap ···················································································· 1E-3 

1.2. 1 Inspe

ction of vice radiator cap

···························································· 1E-3 

1.3  Radiator ·······························································································1E-4 
1.4  Vice water tank ······················································································ 1E-4 

 1.5  Thermostat ··························································································· 1E-4 

1.5.1  Thermostat Dismantling/Mounting …………………………………………………. 1E-4   

1.5.2  Instructions for installing the thermostat······················································1E-5 

1.6 Water Pump  ····························································································1E-5 

   1.6.1  Water Pump Dismantling/Mounting ·························································1E-5 

   1.6.2  Fan Motor························································································1E-5 

  1.7 Fan Relay································································································1E-6 

1.7.1 Inspection of Fan Relay ··········································································1E-6 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Cooling System

 1E-2 

 

1. Cooling System 

Warning on Cooling System Maintenance   

When the engine is running or the engine and heat 
sink are hot, do not dismantle the heat sink lid or 
loosen the heat sink’s drain valve because hot 
coolant and vapor may spout, which will result in 
serious casualties and damage to the engine and 
cooling system   

Turn off the engine, and conduct further operation 
after the engine cools down. Then, keep mindful 
when removing the heat sink’s filler lid, and wrap 
the filler lid with thick cloth and slowly turn it to the 
first stop position along the anticlockwise direction. 
When the pressure declines, turn it along the reverse 
direction;  

If there is not pressure, press the heat sink lid with 
cloth and dismantle it.   

1.1 Engine Coolant   

1.1.1 Inspection of Engine Coolant’s 
Liquid Level   

1.  Confirm if the coolant’s liquid level in 
subsidiary water tank ranges between MAX and 
MIN.  

If the engine coolant’s liquid level stays below 
MIN, open the subsidiary water tank’s lid and add 
the coolant near to the MAX mark.   

If there is no coolant in the subsidiary water tank, 
wait till the engine cools down, and open the heat 
sink’s filler lid to add coolant from the heat sink 
filler port till the coolant’s liquid level can be seen 
from the filler port. Then, mount the heat sink’s 
filler lid, and continue adding the coolant near to 
the MAX mark.   

1.1.2 Replace Engine Coolant 

◆ 

Turn off the engine, and wait for the engine 

coolant completely cool down, removed fixed the 
plumbing and radiator assembly of elastic tube 
outlet folder under the water from the radiator 
assembly out of the outlet to unplug, let go of the 
engine and radiator the coolant assembly. When 
unplug the pipes, be careful not to let the coolant 
splash to humans. 

◆ 

Wait outlet pipes and radiator coolant outflow 

no longer have to re-set in under the water in 
the radiator outlet, and assembled in place and 
re-fix the elastic hose clamp in its original 
location.  

 

◆

After the assembly ended, the reserve tank 

filler injected into the designated coolant, when 
manually add, after the filling is completed, the 
idling operation of the engine a few minutes, 
after the coolant level in the tank drops to be 
deputy, no further exhaust gas cooling system, 
continue to inject cooling fluid, the sub-coolant 
level in the tank to the vicinity of the following 
MAX.

 

Warning 

Alcohol or methanol antifreeze may damage 
aluminum parts on the engine, and so alcohol or 
methanol shall not be used in the cooling system, 
and only the glycol-based coolant can be used.   

Only the softening (demineralization) water can 
be used to mix with the coolant, and water 
containing minerals will compromise the coolant’s 
effect.  

Engine coolant will result in damage to the 
lacquer surface, and so the engine coolant shall be 
rinsed out in no time when it touches the lacquer 
surface.  

◆

  Refer to table below to select appropriate 

volume percentage for mixture of water and 
coolant. Add slowly the coolant into the 
water tank till the coolant reaches the filler 
port.  

Filling speed:1.0L(1.1USqt 、 0.9impqt)/min. 
[Maximum Value] 

Volume 

percentage 

Coolant 

protective agent

Water Coolant 

Proportion at 

20 {68ºF}

℃

 

Higher than 

-16 {3ºF}

℃

 

65 35 

1.054 

 

Cooling System

 1E-3 

 

Higher than 

-26 {

℃

-15ºF} 

55 45 

1.066 

Higher than 

-40 {

℃

-40ºF} 

45 55 

1.078 

 

◆

  Start the engine and maintain the idling speed 

till the cooling fan begins to work.   

Notice 

  If the coolant temperature is over high, stop the 

engine to prevent the coolant from being 
overheated. 

◆

  Conduct the following operations after the 

engine temperature rises: 

(1)  Make the engine run for one minute at the 

rotating speed of 4000rpm; 

(2)  Make the engine run for one minute at the 

idling speed; 

(3)  Repeat Step 1 and Step 2 for several times; 

(4)  Turn on the front/rear heater unit (if has), and 

confirm if there is hot air exhausted from the 
heater unit’s ventilation opening.   

11.  Stop the engine and wait till it cools down.   

12.  Confirm if there is coolant leakage.   

13.  Inspect the coolant’s liquid level. If the level 

is relatively low, add the coolant into the 
subsidiary water tank till it reaches the MAX 
mark.  

1.1.3 Inspection of Engine Coolant 
Leakage  

1.  Inspect the coolant’s liquid level.   

2.  Take off the heat sink lid.   

3.  Connect the heat sink lid tester and SST 

special maintenance tool with the heat sink’s 
filler port.   

Notice 

  If the pressure surpasses 123kPa {1.25kgf/cm2, 

17.8psi}, hose joint and other parts will be 
damaged, which will in turn lead to leakage.   

4.  Make the heat sink reach specified 

pressure: 

Pressure:123kPa{1.25kgf/cm2, 17.8psi} 

 

4.  Inspect if the pressure can be maintained. If 

cannot, inspect if the system suffers coolant 
leakage.  

1.2  

Vice radiator cap

 

1.2.1 Inspection of vice radiator cap   

Warning 

  When the engine is running or the engine and 

heat sink are hot, do not dismantle the heat sink 
lid because hot coolant and vapor may spout, 
which will result in serious casualties and 
damage to the engine and cooling system   

  Turn off the engine, and conduct further 

operation after the engine cools down. Then, 
wrap the vice radiator cap with thick cloth 
carefully, and slowly turn it to the first stop 
position along the anticlockwise direction. 
When the pressure declines, turn it along the 
reverse direction;   

  If there is not pressure, press the heat sink lid 

with cloth and dismantle it.   

1.  Use the SST special service tool to connect 

the vice radiator cap with the tester.   

2.  Increase the pressure little by little.   

 

Cooling System

 1E-4 

 

3.  Inspect if the pressure stays within the 

specified range. If the pressure can keep for 
10s, it indicates that the vice radiator cap is 
normal.  

Pressure range:94-122kPa{0.95-1.25kgf/cm2, 
13.5-17.7psi} 

 

1.3 Radiator 

Radiator Dismantling/Mounting 

Fan Parts Dismantling/Mounting 

1.  Disconnect the accumulator’s negative cable; 

2.  Drain the engine coolant; 

3.  Dismantle the front grille and air intake duct.; 

4.  Remove the radiator and condenser mounting 

bracket bolts bolts; remove the fan mounting 
bolts; 

5.  Remove the engine Water pipe, remove the 

expansion tank hose. (connect with the heat 
sink end); 

6.  Dismantle parts according to the sequence 

illustrated in the table; 

7.  Mount parts according to the sequence 

reverse to the dismantling process.   

 

1 Lower 

water 

pipe 

 

2  Upper water pipe   

3  Fan wiring harness connector 
4 Fan 

assembly 

 

5  Vice-water tank hose I 
6  Vice-water tank hose II 
7  Radiator mounting bracket 

1.4 Vice water tank 

◆ 

Vice

 water tank 

removal / installation 

1. Vice

 water tank 

drained

 

coolant

.

 

2. Dismantle parts according to the sequence 

illustrated in the table; 

3. Mount parts according to the sequ

ence reverse 

to the dismantling process. 

 

1.5 Thermostat 

1.5.1 Thermostat Dismantling/Mounting 

1.  Drain the engine coolant. 

2.  Dismantle parts according to the sequence 

illustrated in the table. 

3.  Mount parts according to the sequence 

reverse to the dismantling process. 

1  Vice-water tank hose I 

2 

Vice-water tank hose III 

3 

Vice-water tank hose II 

4

Vice-water tank bolt 1 

5 

Vice-water tank bolt 2 

 

Cooling System

 1E-5 

 

 

①

 Upper heat sink hose   

②

 Thermostat lid   

③

 O-ring   

④

 Thermostat Mounting Attentions   

1.5.2 Instructions for installing the thermostat 

1.  Mount the thermostat onto the thermostat 

housing, pay attention to the thermostat’s 
direction, with clamping pin facing upward.   

 

Thermostat Inspection   

1.  Inspect thermostat according to items below. 

—Valve temperature when being turned on or off. 

—Valve’s critical temperature in full opening or 

full closing state. If technical requirements 
cannot be met, replace the thermostat.   

Condition Action 

Temperature℃

Initial 
opening  

81 

Temperature rising 
process  

Full 
opening  

93 

Start 
closing  

90 

Temperature 
decline process   

Full 
closing  

79 

1.6 Water pump 

1.6.1 

Water Pump 

Dismantling/Mounting 

See Engine Water Pump Dismantling/ Mounting 
for the water pump dismantling/ mounting. 

1.6.2 

Fan Motor

 

◆ 

Fan Motor Inspection   

1.  Confirm if the accumulator has been fully 

charged. 

2.  Connect the accumulator’s positive electrode 

and amperemeter with the fan motor plug. 

3.  Confirm if the fan motor runs stably while 

being driven by standard current. Replace fan 
motor if it fails to meet technical 
requirements.  

 

Standard Current: 

①

Connected, High-speed Action 11-12.5A [12V] 

①

Disconnected, Low-speed Action 9-10.5A [12V] 

◆ 

Fan Motor Dismantling/Mounting 

1.  Dismantle the cooling fan. 

2.  Dismantle parts according to the sequence 

illustrated in the table. 

3.  Mount parts according to the sequence reverse 

to the dismantling process. 

Clamping pin 

①

 

 

Cooling System

 1E-6 

 

 

1 

Cooling fan heat shielding cover 

2 Cooling 

fan 

blade 

 

3 

Fan motor assembly   

1.7 Fan Relay 

1.7.1 Inspection of Fan Relay 

1.  Disconnect the accumulator’s negative cable   

2.  Dismantle the fan relay from the relay box.   

 

Use the ohmmeter and 12V power supply to 
inspect the fan relay’s quality. If the relay is unable 
to run normally or meet technical requirements, 
replace the fan relay. See table below for the relay 
inspection: 

Step

Port 

Compliance 

standard 

1 

Ohmmeter tests 
resistance at both ends of 
Pin 30 and Pin 87 

Infinite 
resistance  

2 

Both ends of Pin 85 and 
Pin 86 directly link with 
12V power supply   

Hear the 
relay’s 
actuation 
voice  

3 

Keep the relay’s 
actuation state, and again 
use the ohmmeter to test 
resistance at both ends of 
Pin 30 and Pin 87 

Resistance is 
zero  

Remark

High/low-speed relay pins have the 
same definition 

 

Relay Diagram   

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Accessory-Belt

 1F-1 

 

 

Chapter 6  Engine Accessory-Belt   

Table of Contents 

1. Driving Belt ································································································1F-2 

1.1 Inspection of Driving Belt ············································································1F-2 

1.1.1 Inspection of Driving Belt’s Distortion ························································1F-2 

1.1.2 Inspection of Driving Belt Tension·····························································1F-2 

1.2 Adjusting the drive belt ···············································································1F-2 

1.2.1 A/C Compressor Multi-wedge V Belt Adjustment ···········································1F-2 

1.2.2 Power Steering Pump Belt Adjustment ························································1F-3 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Accessory-Belt

 1F-2 

 

1. Driving Belt   

1.1 Inspection of Driving Belt   

If necessary, inspect the driving belt’s distortion 
and tension.   

1.1.1 Inspection of Driving Belt’s Distortion   

Notice: 

  After 30 minutes since the automobile engine 

stops, inspect the belt distortion with a belt 
tensiometer, in order to confirm if the belt 
tension stays within the standard value.   

  If the belt tension goes beyond the specified 

range, adjust the driving belt (see Adjustment 
of Driving Belt) 

 

 

 

1.1.2 Inspection of Driving Belt Tension   

Notice 

  The inspection shall be conducted after the 

engine cools down   

Use SST to inspect the tension of belt between two 
driving wheels.   

  If the tension goes beyond the specified range, 

make adjustment (see Adjustment of Driving 
Belt) 

 

 

1.2 Adjusting the drive belt 

1.2.1 A/C Compressor Multi-wedge V Belt 
Adjustment  

1.  Loosen appropriately the nut on the power 

generator’s pivot bolt.   

2.  Loosen the power generator’s fixing bolt, and 

then tighten it for about 5N.m, in order to 
avoid the pulley’s deflection.   

 

 

3.  Use the adjusting bolt to adjust the belt 

tension and belt deflection to the standard 
value.  

4.  Tighten the power generator’s pivot nut.   

Tightening torque:  43 ±4N·m 

5.  Tighten the power generator’s fixing bolt.   

Tightening torque: 20±2N·m 

 

 

When measuring 

When mounting

Adjust bolt 

Fix power generator bolt 

Power generator pivot nut 

 

Accessory-Belt

 1F-3 

 

 

1.2.2 Power Steering Pump Belt 
Adjustment  

1.  First, loosen the tension pulley’s nut B, and 

then tighten it for about 5N.m, in order to 
avoid the pulley deflection.   

 

 

2.  Adjust the stud bolt A to drive the tension 

pulley’s location change in the tension pulley 
bracket’s slot, so as to adjust the belt tension.   

3.  After the tension meets requirements, tighten 

the tension pulley nut B, Tightening 

torque:40～48N.m 

Notice 

  If mounting new driving belt or running 

driving belt for not greater than 5minutes, 
adjustment shall be made according to the new 
part’s standard value.   

  If running the driving belt for more than 5 

minutes, adjustment shall be made according 
to the old part’s standard value.   

 

 

Distortion (mm/98N) 

Driving Belt 

New 

Old 

A/C Compressor Belt

900N-950N 

(1.5T 

600N-700N) 

500N-600N

Power Steering Pump 

Belt (With Tensioner 

pulley) 

400N-500N 300N-350N

Power Steering Pump 

Belt (Without Tensioner 

pulley) 

300N-500N 

 

Engine Suspension

 1G-1 

 

Chapter 7  Engine Suspension 

Table of Contents 

 

1.Engine Dismantling/Mounting ·········································································· 1G-2 

1.1 Complete the dismantling work ····································································· 1G-2 

1.1.1 Engine1# Suspension Bracket Dismantling/ Mounting ··································· 1G-3 

1.1.2 Engine3# Suspension Bracket Dismantling/ Mounting ····································1G-4 

1.1.3 Engine4# Suspension Bracket Dismantling/ Mounting ····································1G-4 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Engine Suspension

 1G-2 

 

1.

 Engine Dismantling/Mounting

 

Warning 

  Fuel vapor is combustible, and keep away the spark and naked flame.   

Fuel leakage and splash are dangerous, which will irritate the skin and eye. Due to this, follow the “Oil 

Circuit Safety Inspection Procedure” (see Fuel System, Preparatory Work before Repair).   

1.1 Complete the dismantling work 

Respectively discharge A/C refrigerant, power steering liquid, gearbox oil, and engine coolant:   

1.  Disconnect the accumulator’s negative cable. 

2.    Dismantle the engine under the fender (see the engine under the fender removal / installation). 

3.  Dismantle the left/right driving axles (see Driving Axle Dismantling/Mounting). 

4.    Dismantle the engine trim cover (see engine trim cover removal / installation). 

5.  Dismantle the front suspension cross member assembly (see the front subframe of removal / 

installation). 

6.  Dismantle heat sink(see Heat Sink, Heat Sink Dismantling/Mounting).   

7.  Dismantle three-way catalyst converter assembly (see Exhaust System, Exhaust System 

Mounting/Dismantling).  

8.  Dismantle the accumulator and accumulator tray (see Engine Electrical System, Accumulator 

Dismantling/Mounting).  

9. Dismantle PM wiring harness and engine’s connector (see PM Wiring Harness 

Dismantling/Mounting).  

10.  Dismantle the reverse switch joint and gear shift cable that are connected with the gearbox.   

11.  Dismantle the power steering pump hose on the engine, the intake hose connection.   

12.  Dismantle A/C compressor’s pipeline connection.   

13.  Dismantle the engine and engine suspension according to the sequence illustrated in the figure.   

14.  Mount parts according to the sequence reverse to the dismantling process.   

15.   Inject A/C refrigerant and discharge the power steering liquid, gearbox oil, and engine coolant. 

16.  Correct the driving belt’s tension (see Driving Belt, Driving Belt Dismantling/Mounting).   

17.  Star the engine and conduct the following inspection work: 

(1) Inspect the belt pulley and driving belt’s deflection and interference.   

(2) Inspect if there is engine oil, engine coolant, gearbox oil, and fuel leakage.   

(3) Inspect the idling speed (see Engine Running, Idling Speed Inspection).   

18.  Confirm the road test.   

19.  Inspect the engine oil, engine coolant, gearbox oil and power steering liquid’s level again.