Brake system

Brake system
Brake system ................................................................................................................................................... P-1
General steps .................................................................................................................................................... P-2
Conventional brake system .............................................................................................................................. P-2
Air exhaust ............................................................................................................................................... P-2
Inspection and adjustment of brake pedal ................................................................................................ P-3
Removal/disassembly/installation of brake pedal .................................................................................... P-4
Service of brake switch ............................................................................................................................ P-5
Disassembly/installation of brake master cylinder ................................................................................... P-5
Service of liquid level sensor ................................................................................................................... P-6
Disassembly/assembly of brake master cylinder ...................................................................................... P-6
Check of vacuum booster ......................................................................................................................... P-7
Removal/installation of vacuum booster .................................................................................................. P-9

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Check of front disc brakes.............................................................................................................................. P-10
Introduction to the repair tips of brake judder ........................................................................................ P-10
Removal and installation of front disc brakes ........................................................................................ P-11
Removal and installation of the rear disc brake ..................................................................................... P-14
Parking Brake System .................................................................................................................................... P-17
Removal and Installation of Parking Brake Handle ............................................................................... P-17
Removal and installation of rear parking brake ..................................................................................... P-18
Check the parking brake handle ............................................................................................................. P-20
Adjustment of parking brake handle ...................................................................................................... P-20
Anti-lock brake system (ABS control unit) .................................................................................................... P-21
Check of ABS control unit and control unit ........................................................................................... P-21
Steps prior to determine the replacement of the ABS control unit ......................................................... P-23
Exhaust braking ...................................................................................................................................... P-26
Removal and installation of HU/CM of ABS control unit ..................................................................... P-29
Removal and installation of HU/CM of ABS control unit ..................................................................... P-30
Brake line connection diagram of ABS control unit 8 ........................................................................... P-31
Diagram of hydraulic pressure regulator of ABS control unit with ECU............................................... P-32
Definition of hydraulic pressure regulator pins of ABS control unit with ECU .................................... P-32
Removal and installation of wheel speed sensor on the rear ABS control unit ...................................... P-34
Check of Front/rear ABS control unit wheel speed sensor .................................................................... P-35
OBD ....................................................................................................................................................... P-36
ECU faults ...................................................................................................................................................... P-44
 Brake system

General steps
Removal and installation of wheels and tires
1. This chapter does not include the removal and installation steps of wheels and tires. If necessary to
remove the wheel, they shall be retightened up at the installation time, to the specified torque in
88-127N.m {9.0-13.0kgf.m,65-94ft.lbf}.
Disconnection and connection of brake line
Attention
The brake fluid will damage the paint surface, thus, if the brake fluid stained the paint surface, please wipe it
up immediately
1. Use the SST(49 0259 770B ) to screw up the flare nut of brake line, the tightening torque of flare nut on
the brake line has to be adjusted to match with the use of combination tool——joint torque wrench
-SST(See——Moment Equation G1).
2. If the brake line used to be disconnected during the operation, the brake fluid shall be added, air in the
brake system exhausted, then check for any system leakage after the completion of work.
Disconnection of plug

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Attention
1. Prior to the connector operation, the negative connection of battery shall be disconnected, the negative
connection can be remade up only after the completion of work.
Precautions to the operation of ABS control unit component
1. After the work of ABS control unit component completed, no fault codes shall exist in the ABS control
unit system. If there are fault codes in the diagnostic system, eliminate them(See——Fault Diagnostic
Function, ABS Control Unit System, steps to clean up the fault codes).

Conventional brake system

Air exhaust

Attention: 1. Shore up with a jack a vehicle on a level ground

and hold the vehicle on a safe platform.
Whenever, the brake system shall exhaust, when
the brake line disconnected. If the hydraulic 2. Remove the exhaust valve cap from the calipers
piping is disconnected at the brake master and fit up a vinyl pipe, transparent and not
cylinder, the braking shall exhaust by starting corroded by brake fluid on the exhaust bolt.
from the farthest slave cylinder, and then further
3. Place another end of plastic pipe in a clean fluid
wheel cylinder until the exhaust of four
container.
sub-cylinders completed. If the point of
disconnection is not located at the brake master 4. The operator A steps down the brake pedal
cylinder, then the exhaust shall start from the several times, and then hold it on the depressed
nearest disconnection point from the brake slave position. The operator B unscrews the exhaust
cylinders, and then the further wheel cylinder bolt, drains the liquid, the operator A may release
until the exhaust braking 4 of cylinders completed. the brake pedal, after the bleed bolt has been
retightened by the operator B with SST.
Standard of brake fluid:
5. Repeat the steps 4 and 5 until bubbles appear
FMVSS DOT-3
again.
6. During the air exhaust process, the fluid reservoir
shall be held at the 3/4 liquid level to prevent air
reentry again into the pipe.
Tightening torque: 5.9-8.8N·m (60-90kgf·cm)

P-2
 Brake system

7. Check whether the brake is in normal operation.

8. Verify whether there is any spilled fluid, if yes,
wipe it off.
9. When exhausting of the brake is finished, fill the
brake with the brake fluid to the highest liquid
level.

Inspection and adjustment of brake pedal Check of brake pedal height

Confirm that the distance between the central surface
of pedal pad and the carpet is within the designated
range
Pedal height (reference value): 250mm
Adjustment of brake pedal height
1. Disconnect the joint of brake switch.
2. Unscrew the lock nut A and turn the brake light

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switch B until the thread section on the switch
just gets in contact with the pedal limit block.
3. Screw up the lock nut A so that the clearance
between the thread section of switch B and pedal
limit block is within the scope of the technique
requirements.
Technique requirements: 0.1-1.0mm
{0.004-0.039 in}
Tightening torque 14-17 N⋅m {140-180
Height of brake pedal
kgf⋅cm, 122-156 in.lbf}
5. Connect the joint of brake switch.
6. After the adjustment, check whether the pedal
free travel and brake light are in normal
operation.

Check of free travel of brake pedal

1. Step down the pedal several times to clean up
the vacuum from the system.
2. Press down, with hand, the pedal to check the
free travel (until the resistance is felt).
Pedal free travel 6-10mm.

P-3
 Brake system

Clearance between the

brake pedal and the floor

Check of the clearance between the pedal

and floor
1. Start the engine and then confirm that the 2. If the distance from the floor to the center of
distance between the floor to the center of pedal pedal pad is less than the specified value, check

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pad remains within the specified range, when the whether there is air in the Brake system.
pedal is depressed with the force in 147N
{15kgf}.
Specified vale: 130mm (min)

Removal/disassembly/installation of brake pedal

1. Dismantle in the order of 6-7-8-9-10-11-2-3-5-1. 1. Dismantle in the order of
4-12-13-15-14-16-17-19-18
2. Install in the reversing order of removal.
2. Install in the reversing order of removal.

1 Brake switch plug 6 Flange nut 11 Locking bolt 16 Pedal swing arm
2 Stop pin 7 Flange nut 12 M10 Hexagonal nut 17 Limit block
3 Spacer 8 Flange nut 13 Bolt pin 18 Brake light switch
4 Bushing 9 Flange nut 14 Return spring 19 Lock nut M8
5 Vacuum booster push 10 Flange nut 15 Spring sleeve
rod

P-4
 Brake system

Circuit put through

Service of brake switch
Terminal
Conditions 1. Disconnect the connection of brake switch plug.
When the brake is stepped down 2. Connect an ohmmeter between two terminals of
When the brake is not stepped down brake switch plug to check whether the circuit is
put through.
3. If inconsistent to the case as specified in the
table, replace the brake switch.

Disassembly/installation of brake master

cylinder
1. Remove in the order of 1-2-3-4-5-6-7-8. 1 Liquid level sensor plug
2. Install in the reversing order of removal. 2 Pipe clamp

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3 Inlet hose of clutch master cylinder
4 Front cavity pipe of brake master cylinder
5 Rear cavity pipe of brake master cylinder
6 Flange nut
7 Flange nut
8 Brake master cylinder

P-5
 Brake system

Service of liquid level sensor

Circuit put through
1. Pull out the sensor plug;
Conditions Terminal
2. Connect an ohmmeter on the plug;
Below the Min value 3. Start measuring when the liquid level is more
Above the Max value than the max. value, and confirm the circuit is
not through at this moment.
4. Drain out the brake liquid and confirm that the
circuit is through when the liquid level is below
the min. value.
5. If inconsistent to the case as specified in the
table, replace the sensor.

Disassembly/assembly of brake master cylinder

Caution:
If the brake master cylinder body is damaged, the master cylinder shall be replaced. When the master
cylinder is fixed on a bench vice, only the flange disc of master cylinder is to be fixed.

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1. Disassembly as per the order shown in the Table.
2. Assembly in the reversing order of disassembly.

1 Cover component 9 Piston sleeve

2 Screw 10 Retaining ring
3 Fluid tank 11 1st stop pin
4 Bushing 12 1st piston
5 Bushing 13 2nd stop pin
6 Liquid level sensor 14 2nd piston
7 Retaining ring 15 Return spring
8 Butterfly film 16 Master cylinder gasket

P-6
 Brake system

Installation instructions of stop pin

1. Aim the piston bore at the stop pin and fit on the
2nd piston and return spring.
2. Fit on the stop pin.
3. Push in and release the piston to confirm that the
piston can be locked by the stop pin.

Check of vacuum booster

Check the function of vacuum booster (simple method)
Attention:
Replace the vacuum booster when necessary.
Method 1

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1. Shut down the engine; step down the brake pedal several times.
2. Hold pressed the brake pedal and start the engine.
3. If the pedal displaces slight downward after the engine started, it means that the vacuum booster is in
normal operation.
Method 2
1. Start the engine.
2. After the engine run for 1 or 2mins., shut down the engine.
3. Step down the brake pedal by the normal force, and hold it for 3-5s, so to allow the pressure difference
between the front and rear cavities equal to zero.
4. If the 1st travel of stepped pedal is long, and the 2nd becomes shorter, it means that the vacuum booster is
in normal operation.
5. Attention:
If any problems found, inspect whether the check valve and vacuum booster hose are damaged and their
installation, repair or replace when necessary, and then check again.
Method 3
1. Start the engine.
2. Step down the brake pedal by normal force.
3. Hold the brake pedal on the depressed position and shut down the engine.
4. Hold the brake pedal on the depressed position for about 30s.
5. If there is no change in the height of brake pedal, it means that the vacuum booster is in normal
operation.

P-7
 Brake system

(Check with a measuring instrument)

Vacuum gauge

Pedal dynamometer

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1. As shown in Fig., connect respectively with the SST vacuum gauge and pedal pressure detector.
Attention: Exhaust the air in the SST at the instrument A with a special instrument and a pedal pressure
detector.
2. After the air exhausted from the SST, detect as per the following steps:

a) Check the vacuum leakage

Under no-load:
1. Start the engine.
2. When the vacuum gauge reading reached 66.7kPa{500mmHg}, shut down the engine.
3. Shut down the vacuum gauge for 15s. If the vacuum indicates 63.3-66.7kPa {475-500mmHg}, it means
that the vacuum booster is in normal operation.

Under loading conditions

1. Start the engine.
2. Step down the brake pedal with the force in 196N {20kgf}.
3. Hold depressed the brake pedal, and shut down the engine when the vacuum gauge reading reached
66.7kPa {500mmHg}.
4. Observe the vacuum gauge for 15s. If the vacuum degree indicates 63.3-66.7kPa {475-500mmHg}, it
means that the vacuum booster is in normal operation.

b) Check the hydraulic pressure

1. Shut down the engine (vacuum degree: 0kPa {0mmHg}. If the fluid pressure is now within the specified
range, it means that the vacuum booster is in normal operation.

Pedal pressure Fluid pressure

196N{20kgf} 790kPa{8kgf/ cm2}min

P-8
 Brake system

2. Start the engine and step down the brake pedal when the vacuum degree achieved 66.7kPa{500mmHg}.
If the fluid pressure is within the specified range, it means that the brake device is in normal operation.

Pedal pressure Fluid pressure

MTX 196N 7100kPa{72kgf/cm2}min
ATX {20kgf} 8820kPa{90kgf/cm2}min

Removal/installation of vacuum booster

1. Remove the brake master cylinder
(See——Conventional brake system,
Removal/installation of brake master cylinder).
2. Remove in the order as shown in the Table.
3. Assembly in the reversing order of disassembly.
1 Vacuum booster hose assembly
2 Spring pin
3 Axle pin

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4 Nut
5 Vacuum booster pump
6 Check valve assembly

P-9
 Check of front disc brakes

Check of front disc brakes

Introduction to the repair tips of brake judder
There are three features as shown below in the problems of brake judder:
(1) Vibration of steering wheel. The steering wheel vibrates in the direction of rotation and such feature is
the most notable when braked at the speed between 100～140 km/h {62～87 mph};
(2) Floor vibration. In braking, the bodywork vibrates forward and rearward, and the vibration intensity is
not subject of the speed effect;
(3) Vibration of brake pedal. When the brake applied, there is impulsive force trying to push back the brake
pad, and transferred on the brake pedal.
The followings are some key raisons possibly resulting in brake judder:
When the brake disc jittered too much, the swing thickness between the one side and another is uneven. If the
judder is over 0.05 mm {0.002 in} at 10 mm {0.39 in} away from the edge of brake disc, it means the uneven
wear on the disc occurred due to the contact of the unbalances of pad and disc, if it is less than 0.05 mm
{0.002 in}, it means that no uneven wear occurred.
Thermal deformation of disc The repeated violent brakes may enable the disc local temperature to increase up
to about 1000℃ {1832ºF}, resulting in the disc distortion.

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The thickness and friction coefficient of disc will change due to corrosion. If the vehicle parked for longtime
in wet condition, the friction surface of disc will be corroded. When the corrosion thickness is uneven, it will
take the corrugated shape, resulting in the variation of friction coefficient and the reaction force.
Check and repair process
Identify the complains of clients

Carry out the radial run-out check More than 0.05mm (0.002in)
Refer to Radial Run-Out Check
Less than
Less than 0.05mm 0.05mm
Presence
(0.002) (0.002)
Confirm whether there have Remove the disc plate,
been any brake jitters reinstall at another phase and
Not presented make again the radial run-out
Check the thickness variation (see check.
below) More than 0.015mm (0.0005in)

More than
Less than 0.015mm (0.0005in) 0.05mm
(0.002in)
Verify the repair
Use the mold on the vehicle to
process the d isc p late

Tighten all rim nuts by the same

torque to fix the brake disc and
measure the radial run-out.

Use the mold on the vehicle.

[Less than 0.015mm (0.0005in)]

Work completed

Check the lateral run-out

1. Screw up, in crosswise, the hub nut to assure that the disc and hub properly were installed or the washer
inserted between the hub bolt and hub nut with the spacer thickness in10mm {0.39 in} and the I/D more
than 12 mm {0.47 in}.
Note:
The part composed by SST 49 B017001 or 49 G019 003 may be use as the suitable washer.

P-10
 Check of front disc brakes

2. After all hub nuts screwed up to the same torque, place the dial gauge on the friction surface of brake
disc, at ca.,10 mm{0.39 in} away from the edge of disc.
3. Turn once the brake disc and measure the lateral run-out.
Run-out limit: 0.05 mm {0.002 in}.

1. Clean up with brake cleaner the friction

surfaces of brake disc and brake pad.
2. Measure, with a micrometer calipers, the
thickness of each point as shown in the figure.
3. Subtract, with the measured maximum value the
minimum value. If the result is nonconforming
to the requirements, process the brake disc with
grinding tool.
Variation limit of thickness: 0.015 mm {0.0005
in}
Warning
Don’t surpass the requirements of minimal brake disc

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thickness.

Check the variation of thickness

Check the thickness of brake disc
Attention
If the disc is removed from the vehicle for processing, it will result in excessive run-out, thus the disc shall be
processed when fitted up on the vehicle.
1. Measure the thickness of disc. Replace the disc when the disc thickness is not within the range of
technique requirements, then,
The minimal thickness limit of front brake disc: 24 mm {0.94 in}
The minimal thickness limit of rear brake disc: 10 mm {0.39 in}

Check the thickness of brake pad

1. Jack up the front part of vehicle and shore it up
with the safety bracket.
2. Remove the wheel.
3. Check the residual thickness of pad and replace
the pad by full set. As long as the thickness of
one lateral pad of R/L wheels is less than or
equal to the requirement of minimal thickness,
the pads at both sides should be replaced at the
same time.
Pad thickness required: minimum value: 2.0 mm
{0.08in}

Removal and installation of front disc brakes

1. Remove in the order as shown in the Table
2. Assemble in the reversing order of disassembly
3. After installation step down the brake pedal several times, turn manually the wheel to confirm that no
brake blocking exists.

P-11
 Check of front disc brakes

1 Brake hose 7 Guide pin cover

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2 Caliper bolt 8 Guide pin
3 Front caliper assembly 9 Guide pin bushing
4 Compressing spring 10 Front brake disc
See——P Essentials to Removal of
5 Internal/external friction plate
Brake Disc
See——P Essentials to the Installation of See——P Essentials to Brake Disc
Internal/External Friction Plates Installation
6 Support beam 11 Bleed screw and bleed screw cap

Wood plate

Mark

Essentials to the installation of internal

/external friction plate
1. Push down to the end the piston with SST
Essentials to removal of brake disc 2. Install the brake pad
1. Prior to the removal, make the mark on the hub
bolt and brake disc for the reference at the
Replace the internal/external friction plate
installation time. 1. Disassemble in the order as shown in the Table.
Essentials to the installation of brake disc 2. Assemble in the reversing order of disassembly
1. Clean up any rust or grime on the contact
surface of brake disc and hub.
2. Align with the mark made prior to the removal
and fit up the brake disc.

P-12
 Check of front disc brakes

1 Guide pin cover

2 Guide pin
3 Compressing spring
4 Internal/external friction plate
5 Support beam
6 Brake caliper assembly

Disassembly and assembly of front brake

caliper
1. Disassemble as per the order shown in the
Table.
2. Assembly in the reversing order of disassembly

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1 Piston dust cover
2 Piston
See——P Essentials to the
Disassembly of Piston
3 Piston gasket
See——P Essentials to the
Disassembly of Piston Gasket
4 Bleed screw cover
5 Bleed screw
6 Front caliper body

Essentials to the piston disassembly

Attention
Slowly blow the compressed air into the brake caliper
to prevent sudden run-out of piston.
1. Place the SST into the brake caliper and then
slowly blow the compressed air from the hole
into the brake caliper, enabling the piston to be
pushed out from the brake caliper.

P-13
 Check of front disc brakes

Essentials to the Disassembly of Piston Seal

Ring:
1. Push out, with the SST, the piston seal ring from
brake calipers.

Removal and installation of the rear disc brake

1. Remove in the order as shown in the Table
2. Assemble in the reversing order of disassembly
3. After installation, step down the brake pedal several times, turn manually the wheel to confirm that no

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brake blocking exists.

See——P Essentials to the Installation of

1 Hollow bolt
Internal/External Friction Plate
2 Rear brake hose 7 Rear brake disc
See——P Essentials to the Removal Brake
3 Guide pin cover
Disc
See——P Essentials to the Installation of
4 Guide pin
Brake Disc
5 Rear caliper assembly 8 Guide pin sleeve
6 Internal/external friction plate 9 Bleed screw and bleed screw cover

P-14
 Check of front disc brakes

Brake disc removal essentials

Prior to the removal, mark on the hub bolt and brake
disc for reference at the installation time.
Mark
Essentials to the Installation of Brake Disc
1. Clean up any rust or grime on the contact
surface of brake disc and hub.
2. Align with the mark made prior to the removal
and fit up the brake disc.

Essentials to the Installation of

Internal/External Friction Plate
Wood plate
1. Push out, with the SST, the piston to the end.
2. Install the brake pad.

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Replacement of the Internal and External
Friction Plate
1. Disassemble in the order as shown in the Table.
2. Assemble in the reversing order of disassembly

1 Guide pin cover

2 Guide pin
3 Internal/external friction plate
4 rear brake caliper
5 Guide pin sleeve

P-15
Check of front disc brakes

Disassembly/assembly of rear brake

calipers
1. Disassemble as per the order shown in the
Table.
2. Assembly in the reversing order of disassembly

1 Piston dust cover

2 Piston
See——P piston disassembly
essentials to the
3 Piston gasket:
See——P piston gasket disassembly
essentials to the
4 Bleed screw cover
5 Bleed screw
6 Rear caliper body

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Piston disassembly essentials to the
Attention
Slowly blow the compressed air into brake caliper to
prevent sudden run-out of piston.
1. Place the SST into the brake caliper and then
slowly blow the compressed air from the hole
into the brake caliper, enabling the piston to be
pushed out from the brake caliper.

Essentials to the Disassembly of Piston

Gasket
1. Remove with the SST the piston gasket from
the brake calipers.

P-16
 Parking Brake System

Parking Brake System

Removal and Installation of Parking Brake Handle
1. Disassemble in the order as shown in the Table.
2. Assemble in the reversing order of disassembly.
3. Adjust the travel of parking brake handle.

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Auxiliary instrument panel: See——S Support spring and clamping pin of
1 9
Auxiliary Instrument Panel brake shoe
Mounting bolts of parking handle and
2 10 Upper/lower return springs
bracket
3 Parking brake handle 11 Parking adjustment mechanism
4 Mounting bolt of parking cable 12 Push plate and brake plate assembly
5 Guide pin cover 13 Brake shoe
6 Guide pin Front draw wire and rear parking
14
7 Rear brake calipers inhaul cable assemblies(L/R)

8 Rear brake disc 15 Parking handle holder

P-17
 Parking Brake System

Removal and installation of rear parking brake

1. Disassemble in the order as shown in the Table.
2. Assemble in the reversing order of disassembly.
3. After installation, adjust the brake shoe clearance and carry out the following jobs.
(1) Step the brake pedal several times and then confirm that no brake blocking exists
(2) Check the clearance between the pedal and floor.
(3) Check the travel of parking brake handle.

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1 Rear brake disc 6 Parking adjustment mechanism
2 Clamping pin 7 Parking brake shoe assembly
3 Brake shoe support spring 8 Rear parking cable
4 Upper return spring 9 Push plate and brake plate assembly
5 Lower return spring 10 Rear mudguard

P-18
 Parking Brake System

Check the thickness of parking brake shoe

1. Remove the lower brake disc;
2. Check the thickness of residual friction plate;
● As long as the thickness of one of R/L friction
plates is less than or equal to the minimal
thickness, the brake shoes at both sides should
be replaced at the same time.
Friction plate thickness:
Minimum value: 1.0 mm {0.04 in}

Check the inner drum head of rear brake

disc
1. Measure the I/D of the drum head of rear brake

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disc.
I/D maximum value: 188 mm {7.40 in}

2. Check whether there are any scratches,

unevenness or abnormal wear on the inner
drumhead of rear brake disc.
3. Repair or replace the rear brake disc if
necessary.
4. Pay attention to check whether the drumhead is
in good contact with the brake shoe when the
rear brake disc is repaired or replaced.

Essentials to the removal of rear brake disc

removal
1. Prior to the removal, mark on the hub bolt and
Mark rear brake disc for reference at the installation
time.

P-19
 Parking Brake System

Essentials to the installation of parking

brake shoe
Note: Toggle up to tighten the parking adjustment
mechanism.
1. Clean up any rust and grime on the contact
interface of drum brake.
2. Align with the mark made prior to the removal
and fit up the brake drum.
3. As steps stated below, adjust the clearance of
brake shoe.
Parking adjustment mechanism (1) Clean up any rust and grime on the contact
interface of inner drum of rear brake disc.
(2) Align with the mark made prior to the removal
and fit up the rear brake disc.
(3) Poke, with a screwdriver, the parking adjustment
mechanism, through the parking adjusting hole
on the rear brake disc until the parking shoe disc

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fully got in tight contacted the brake disc.
(4) Poke downward the parking adjustment
mechanism for 3～5 teeth by the same method,
to assure the free rotation of brake disc.

Parking adjustment hole

Check the parking brake handle

1. Pull the parking brake handle several times.
2. Pull, by the force in 98 N {10 kgf, 72.3 ft.Ibf}, the parking brake handle and check the travel of parking
brake for 3－7 teeth.

Adjustment of parking brake handle

Adjusting nut

1. Pull apart the jacket zipper of parking handle.

2. Turn the adjusting nut on the front parking cable.
3. After the adjustment, check the following points:
(1) Turn on the ignition switch, pull the parking brake handle for one tooth to confirm that the parking brake
light is lit.
(2) Confirm that no brake blocking exists on the rear brake.

P-20
 Anti-lock brake system (ABS control unit)

Anti-lock brake system (ABS control unit)

Check of ABS control unit and control unit
Check of the system
Precautions to the maintenance diagnostics of ABS control unit
The ABS control unit concerns the safety parts; therefore, the following diagnostic precautions have to be
taken when other than in compliance with the general safe and preventive measures while other maintenance
diagnostics are carried out.
(a) The ABS control unit system has to be maintained by the technicians having received the professional
training and mastered the maintenance skills, and only original parts are allowed to use for replacement.
(b) Prior to the diagnostics of ABS control unit system, the conventional brake system shall run in normal
operation.
(c) Before and during the drive, the ECU of ABS control unit continuously monitors whether all electric
elements relevant to the ABS control unit are in sound operation.
(d) When the ignition switch turned on, the ABS control unit and EBD LIGHT have to be lit up, and in few
seconds, the ABS control unit and EBD alarm light shall go off in case of no faults in the system.

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Note: The EBD alarm light and parking light are for public use. When the parking handle is pulled
up and the brake fluid too little, the alarm light will lighten up.
(e) The following two cases indicate that there are faults detested in the system:
① After the ignition switch turned on, the warning light will be held lit up for longtime;
② Do not go off once lit up in the driving process.
At this time, the driver may also perform the brake and minimize as much as possible the application of
braking force to prevent the blockage of wheel. Hence, cares must be taken to drive after the warning
light lit and have the ABS system checked and repaired at a special service station to prevent occurrence
of more faults, resulting in traffic accident.
(f) The hydraulic pressure regulator of ABS control unit with ECU comprises the following parts:
① ECU of ABS control unit: motor relay with reflux pump and solenoid relay;
② Solenoid (8pcs): including 4 inlet valves and 4 outlet valves;
③ Reflux pump and accumulator;
④ Others: motor and bolts etc.
They can be replaced by complete unit instead of being knocked down or partially replaced/exchanged.
No individual spare-part will be supplied. And no warranty will be undertaken for the ABS control unit
knocked down and equipped with the hydraulic pressure controller. No responsibility will be taken for
adverse outcomes resulted after the hydraulic pressure regulator of ABS control unit disassembled for
check or partially replaced /exchanged
(g) Connection of ECU of ABS control unit.
① The ignition switch has to be disconnected when the ECU connector of ABS control unit is unplugged;
② Assure that the ECU connector of ABS control unit is kept dried and clean and no existence of any
foreign matters exists;
③ ECU connector of ABS control unit has to be installed in place: the lower part levels with the pedestal;
④ ECU connector of ABS control unit has to be installed in place: the lateral part is perpendicular to the
pedestal.
(h) The hydraulic pressure regulator of ABS control unit with ECU must be well grounded.

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 Anti-lock brake system (ABS control unit)

For the imperfect measure of harness grounding, the connector, where water and moisture ingress, under
the effect of siphon, through the pore passages in the harness, into the ECU of ABS control unit, will
cause the function ineffective.
Measures taken: Smear sealant on the bare end of harness and apply the heat-shrink tube envelope.
Recommend use for sealant: Raychem sealant.
(i) When connecting the brake line of ABS control unit brake line, the correct connection has to be assured.
The ECU of ABS control unit is neither unable to judge whether the brake line is properly connected, nor
to perform the fault protection. Wrong connection may result in serious accidents.
The marks on the hydraulic pressure controller of ABS control unit vary depending to different
production places:
MC1: in connection with the brake line 1 of brake master cylinder;
MC2: in connection with the brake line 2 of brake master cylinder;
FL: in connection with the brake line of cylinder on the left front brake wheel cylinders;
FR: in connection with the brake line of cylinder on the right front brake wheel cylinders;
RL: in connection with the brake line of cylinder on the left rear brake wheel cylinders;

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RR: in connection with the brake line of cylinder on the right rear brake wheel cylinders;
(j) The correct connection of wheel speed sensor has to be guaranteed.

Tightening bolts (4pcs)

ABS control unit (with

reflux pump motor and
solenoid relay)

Solenoids (8pcs) [4
input valves and 4
output valves] Hydraulic
controller

Reflux pump
motor

Check the ABS control unit prior to the diagnostics

1. Be sure that the recommended specifications of tire and wheel are installed on the vehicle. The coaxial
style pattern and depth must be consistent.
2. Check whether there are any leakages in the hydraulic pressure regulator, brake line and connector.
3. Check the ABS control unit fuse.
4. Be sure that the battery has been fully charged.
5. Check whether there is any uncleanness in the battery connection or any looseness of terminals. Be sure
of the good grounding.
6. The parts of ABS control unit are very sensible to the electromagnetic interference. If any intermittent
faults suspected, check whether the anti-theft device and on-board mobile phone added after sales are
correctly installed.

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 Anti-lock brake system (ABS control unit)

Noise
1. Self-tested sound system
After the engine started, short noise “Buzz” will come out from the engine compartment when a running
vehicle reached at 15km/h. It is a normal phenomenon as noise produced by the self-test of ABS control
unit.
2. Sound when the ABS control unit plays role
a. Motor sound from the hydraulic pressure unit of ABS control unit
b. Noise produced by the vibration together with the brake pedal
c. During the operation of ABS control unit, impact noise of suspension produced by the braking
3. If the noise is too loud when the system makes the self-test or the ABS control unit plays role, it
may be caused by the following reasons:
a. The fixation of ABS control unit and holder is loosened;
b. The fixation of ABS control unit holder with the bodywork is loosened
c. The connection fixing the brake lines is loosened
d. There are bulbs in the brake line.

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Steps prior to determine the replacement of the ABS control unit
Dynamically self-check:
1. After the troubleshooting, the speed shall not be lower than 15km/h to enable the ABS control unit for a
dynamically self-check.
2. As the ABS control unit fault light will keep will not go off, the re-ignition is necessary after the
troubleshooting (e.g. the wheel speed sensor signal unstable or motor fault). Only when the vehicle
reached to about 15km/h and after the ABS control unit passed through the dynamically self-check, the
ABS control unit fault light can go off.
Cross validation:
Remove the ABS control unit and install on another trouble-free vehicle using an ABS control unit of same
model. It is only necessary to plug in the connector of ABS control unit sensor harness instead of oil pipe.
Reignite the vehicle and suspend it on a lifter and have it turn on air. Let the ABS control unit carry out the
dynamically self-check with the speed not lower than 15km/h.
1. If the alarm light of ABS control unit is still lit, it indicates that faults really exist in the ABS control unit.
The ABS control unit can be replaced.
2. If the alarm light of ABS control unit is off, it indicates that there are no faults in the ABS control unit.
Please rearrange the investigation as per the service manual
When operating according to the above steps, be sure that the ABS control units on two vehicles are of
same model and the ABS control unit plug tightly plugged in, otherwise it will result in unstable circuit.
Poor contact will cause the signal of wheel speed sensor distorted.
Requirements relevant to the Haima vehicle analysis for the product reject
The product warranty period provided by the Haima vehicle to the customer is 2 years, i.e. 60,000kms.
For the products, which are returned for the Haima vehicle analysis, an visual check shall be made at
First with the items as below:
1. No visual damages on the product
2. The ABS control unit not yet disassembled
3. No scratches on the ECU pins of ABS control unit

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 Anti-lock brake system (ABS control unit)

4. No rust and water stain on the ECU slot of ABS control unit
Relevant Information to be supplied by the customer for the failure analysis made on the Haima vehicle:
1. Information of dealer/maintenance and repair network
2. What diagnostics have been made by the fault information description as well as the maintenance and
repair network?
3. Mileage
4. Dates of fault and maintenance
5. When the fault came about, e.g.: speed, roadway and environment etc,.
6. VIN code
Preparations
1. Be sure that the vehicle is only fitted up with the tires and wheels of recommended size and the coaxial
style pattern same as the depth.
2. Check whether there are any leakage in the hydraulic pressure regulator, brake line and connector.
3. Check the fuses of ABS control unit——10A, 25A and 40A. Be sure to only use the fuse of correct size.

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4. Confirm that the battery has been adequately charged;
5. Turn the ignition switch in the ON position. Confirm that the alarm light of ABS control unit goes off in
2—4s. If the alarm light keeps lit in 2-4s, it means that the control modular of ABS control unit has
detected the faults and won’t trigger the hydraulic pressure unit of ABS control unit. Carry out the
maintenance of Fault Diagnosis Process;
6. Turn the ignition switch to Off;
7. Jack up the vehicle on a level ground by use of a jack, shore up the vehicle on a safety seat, and shift the
gearbox on the N position.
8. Release the parking handle.
9. Turn manually the wheel to check whether there are any scratches on the brake.
Use of SST
(1). Complete the preparations
(2). Connect the NGS tester of SST to the joint of data connection;
Note: Perform by use of the manual in compliance with the SST NGS instruction.
(3). Set up the active control mode as per the following combination order. Check the (See——P ABS
control unit OBD)

Name of order
VP
Function Type of orders
PMP motor RF outlet RF inlet WR
RLY
Pressure maintenance Off Off On On
Manual
Pressure reduction On On On On

Above is an example of right wheel inspection

Note: In case of the work performed by two persons, one should step on the brake pedal while the other tries
to turn the checked wheel.
(4). Step the brake pedal and give the order while trying to turn the checked wheel.
(5). While holding the pressure, the clicks out of the ABS control unit HU/CM indicate that the solenoid is in
normal operation. Confirm that the wheels are not rotatable. When reducing the pressure, the clicks out

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 Anti-lock brake system (ABS control unit)

of ABS control unit HU/CM mean that the solenoid works properly. Confirm that the wheels can rotate
even if the brake pedal was depressed.

Non-use of SST 1. Completion of preparations

Jumper Attention：Wrong connection with the data cable
may result in faults. Therefore， carefully make
connection, which is only allowed to the specified
terminal.
2. Connect by use of a jumper, the TBS terminal of data
transmission plug with the GND terminal;
3. Step down the brake pedal and have your assistant
confirm that the front wheel is unable to rotate.
4. Hold the brake pedal stepped and turn the ignition
Ignition switch
switch in the ON position. Confirm that the brake will
be released in an instant (ca., 0.5S), and the wheels can
be rotated when the pressure is reduced.
s s
Pressure 5. Check, in sequence, the operations of other wheels:
Low right front; left front; right rear and left rear.

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Normal
Right Left Right Left
Note:
Motor
front front rear rear s · If the wheels do not rotate，replace the hydraulic
unit of BS control unit;
· If the wheel runs, but in wrong sequence, check
the brake pipe in connection with the hydraulic
unit of ABS control unit.
Attention:
· If the operation is proved normal by the steps 4
and 5, it indicates that the system is normal:
— In connection with the hydraulic unit brake oil of
ABS control unit
— Including the hydraulic unit brake system of ABS
control unit.
— Electric systems inside the ABS control unit
hydraulic unit (solenoid valve, ABS control unit
and motor etc.,)
— Control module of ABS control unit, output
system and harness of control module.
The above steps excluding the check of the following
items:
— The input system and harness of ABS control unit
control module.
— Intermittent fault.
— Liquid leakage.
6. Turn the ignition switch in the OFF position and
remove the jumper connecting the TBS and GND
terminals.

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 Anti-lock brake system (ABS control unit)

Exhaust braking
1. The brake system can be exhausted artificially. The customer service may choose the following three
exhaust processes:
— To exhaust by a filling unit (2 bar exhaust)
— To exhaust by the artificial pedal
— To exhaust jointly by the artificial pedal and filling unit.

Statement:
● The exhaust braking can be executed during the processes of the first loop and the second loop.
● After the customer replaced the brake system elements (e.g. replace the brake fluid and braking system
elements, hydraulic pressure unit), or the brake pedal became softer, the exhaust has to be made.
● The hydraulic pressure unit replaced by the customer has to be wet typed ABS control unit with ECU.
● During the exhaust process, it must be assured that the brake system is in complete structure and all HP
hydraulic pressure units are in sound connection.
● Prior to the exhaust, it is necessary to set the gear position in the N-position and pull up the parking

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handle.
● As the brake fluid is somehow corrosive. If stained on your skin by imprudence, you have to clean it up.
2. To exhaust by use of an exhaust/filling unit (exhaust for 2 bars)

Connect the exhaust/filling unit to the liquid storage tank, confirm that there is
A sufficient braking liquid to turn on the switch. Set up the pressure to 200bars

Open the release screw at the left wheel cylinder until the bubbles are exhausted.
B

Check the travel of pedal

C

If failed, repeat the exhaust of every wheel

D

Check the level of braking liquid and assure that it is kept between the max. and min.
E
levels.

3. Artificial pedal exhaust

Fill up the liquid storage tank(until reached over the filter neck)
A

Repeat the following procedure to exhaust the air in each wheel cylinder.
B Sequence: left rear; left front; right front and right rear.

Open the exhaust screw

C

Repeatedly step down the brake pedal

D

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 Anti-lock brake system (ABS control unit)

Close the exhaust screw

E

Release the brake pedal

F

Check the travel of pedal

G

If failed, repeat the air exhaust

H

Check the level of brake liquid, and assure that it is kept between the max. and min.
J
levels.

4. Exhaust by artificial pedal in combination with the exhaust by filling unit

Connect the exhaust/filling unit to the liquid storage tank, confirm that there is
sufficient braking liquid to turn on the switch. Set up the pressure to 200bars
A

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Repeat the following procedure to exhaust the air in each wheel cylinder.

B Sequence: left rear; left front; right front and right rear.

Repeatedly step the brake pedal

B1

Check the travel of pedal

C

If failed, repeat the exhaust of every wheel

D

Check the level of brake liquid and assure that it is kept between the max. and min.
E
levels.

Remark:
● The recommended sequence for X –loop: left rear, left front, right front and right rear
● If decreasing the pressure before opening the screw. The correct grade of filling is normally set
automatically
● During the whole exhaust process, the brake fluid in the tank (container) cannot be lower than the lowest
scale.
5. Artificial exhaust diagram
Artificial exhaust diagram of X-loop of 4-way ABS control unit: left front wheel

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 Anti-lock brake system (ABS control unit)

X- braking look

Vacuum degree: 2bars

Braking look 2 Braking look 1

Backflow 2 Backflow 1

Right front Left rear input Right rear Left front

input valve Accumulator valve input valve Accumulator input valve

Right front Left rear Right rear Left front

output valve output valve output valve output valve

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X- braking look

Vacuum degree: 2bars

Braking look 2 Braking look 1

Backflow 2 Backflow 1

Right front Left rear input Right rear Left front

input valve Accumulator valve input valve Accumulator input valve

Right front Left rear Right rear

Left front
output valve output valve output valve
output valve

Function mode:
The brake fluid flows, through the master cylinder and hydraulic pressure unit, into wheel cylinder. Open the
bleed screw on the left front wheel, the bleed screws on other wheel are closed. Repeatedly step on the brake
pedal until the bubbles and impurities have been cleaned out and the brake fluid purified. Repeat the same
procedure on other three wheels.

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 Anti-lock brake system (ABS control unit)

Removal and installation of HU/CM of ABS control unit

Caution
● Do not let the ABS control unit drop down to the floor. If they are subject of an impact, then they shall be
replaced.
Attention
● The pressure unit of ABS control unit hydraulic is purchased as an integrated part with the control
modular of ABS control unit. If any one of two functions lost efficacy, the pressure unit of fault ABS
hydraulic or fault ABS control modular shall be replaced entirely instead of separately.
1. Remove the air filter assembly, battery and intake hose.
2. Remove as per the order as shown in the Table.
3. Install in the reversing order of removal.

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1 Harness connector 8 Nut
Driven cavity tubing of brake master
2 9 Nut
cylinder
Drive cavity tubing of brake master
3 10 ABS control unit modular
cylinder
4 Right front brake lines assembly 11 Locking bolt
5 Left front brake lines 12 Locking bolt
6 Front end of left right brake line 13 Locking bolt
7 Front end of right rear brake line 14 ABS control unit holder

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 Anti-lock brake system (ABS control unit)

Removal of plug
l Confirm that the locking rod of plug is
completely tightened;
l Pull up completely the locking rod at the
removal time;
l Pull out the ABS electric connector.
Thrust bar

Removal and installation of ABS control

unit holder
1. Removal and installation bolt.
2. Remove the ABS control unit holder.
3. Remove the ABS control unit.
4. The installation process is in the reversing order

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of removal process.

1 Nut 6 Locking bolt

ABS control unit
2 Nut 7
holder
ABS control unit
3 8 Buffer cushion
modular
4 Locking bolt
5 Locking bolt

Removal and installation of HU/CM of ABS control unit

Direction where the
force is applied
1. Initial state

2. Fit up the left buffer

element (facing the engine)

Direction where the

force is applied
3. Insert the central pin

4. Install the nut

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 Anti-lock brake system (ABS control unit)

Brake line connection diagram of ABS control unit 8

Vacuum booster
Braking liquid tank

Brake master pump

Braking pedal

Braking pipe of master pump 2 Braking pipe of master pump 1

ABS hydraulic regulator

Motor of backflow
Damper pump Damper
Backflow pump 2 Backflow pump 1

Left rear input Left front

Check Right front input valve valve Right rear input valve input valve
Accumulator Accumulator
valve
(4)

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Right front output valve Left rear output valve Right rear output valve Left front output valve

Brake slave Brake slave Brake slave

Brake slave
pump pump pump
pump

Right front Left rear Right rear Left front

wheel wheel wheel wheel

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 Anti-lock brake system (ABS control unit)

ECU terminal definition

Diagram of hydraulic pressure regulator of ABS control unit with ECU

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Check the HU/CM of ABS control unit
1. Disconnect the negative connection of battery.
2. Turn off the ignition switch and the tester
between the HU/CM of ABS control unit and
harness joints.
3. Connect the lead of tester to the special tool, and
check the terminal voltage according to the
following table.

Definition of hydraulic pressure regulator pins of ABS control unit with ECU

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 Anti-lock brake system (ABS control unit)

Terminal Code Implications Testing Standard voltage

12V continuous power supply-40A
1 UBMR ←→GND(38) 9.3～16.9
fuse MOTOR
Warning light of active ABS control
4 NEBVSILA ←→GND(38) 9.3～16.9
unit
Speed sensor signal of right front
6 FR WS
wheel
13 MGND Motor of grounding reflux pump Battery negative ＜0.5V
17 DIAGK Diagnostic wire-K ←→GND(38) 9.3～16.9
18 FR WP Speed sensor PS of right front wheel ←→GND(38) 9.3～16.9
19 RR WP Speed sensor PS of left rear wheel ←→GND(38) 9.3～16.9
20 RL WS Speed sensor signal of left rear wheel
22 FL WS Speed sensor signal of left front wheel
12V continuous power supply-25A
25 UBVR ←→MGND(13) 9.3～16.9
fuse VALVES

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28 VSO Speed signal output
NABS control
16 Active EBD warning light ←→GND(38) 9.3～16.9
unit SILA
9.3～16.9
30 BLS Brake light switch (+) ←→GND(38)
0
31 RR WS Speed sensor signal of right rear wheel
32 UZ Ignition switch SP-DIN15 ←→GND(38) 9.3～16.9V
33 RL WP Speed sensor PS of left rear wheel ←→GND(38) 9.3～16.9
34 FL WP Left front wheel speed sensor PS ←→GND(38) 9.3～16.9
38 VGND Grounding- ECU of ABS control unit ←→GND(13) ＜05V

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 Anti-lock brake system (ABS control unit)

Removal and installation of wheel speed sensors of front/rear ABS control units
1. Disassemble in the order as shown in the Table, the wheel speed sensor of front ABS control unit (R
same as L).
2. Assemble in the reversing order of disassembly.

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1 Connector of front wheel speed sensor
2 Locknut
3 Locking bolt
4 Locking bolt
5 Upper holder of speed sensor on the left front wheel
6 Lower holder of speed sensor on the right front wheel
7 Harness of front wheel speed sensor

Removal and installation of wheel speed sensor on the rear ABS control unit

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 Anti-lock brake system (ABS control unit)

1. Remove the trim plate of rear trunk. 1 Harness joint of rear sensor

2. Remove as per the order as shown in the Table. 2 Locking bolt

3. Install in the reversing order of removal. 3 Locking bolt

4 Locking bolt
5 Locking bolt
6 Harness of rear wheel sensor

Check of Front/rear ABS control unit wheel

speed sensor
Visual inspection
ABS wheel sensor
1. Remove the wheels and tires to check whether
the wheel speed sensor is loose or damaged.
Replace them when necessary. Clearance
Inspection of air gap
1. Check the clearance between the wheel speed
sensor and sensor.

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Clearance: 0.2 --1.3 mm {0.007 --0.051 in}.
Gear rim of ABS sensor
Inspection of resistance value
1. Disconnect the wheel speed sensor joint of ABS
control unit.
2. Check the resistance of wheel speed sensor of
ABS control unit
If the resistance value doesn’t meet the
requirements, replace the wheel speed sensor.
Resistance value: 75 KΩ±1%

Inspection of current
1. Jack up the vehicle on a level ground by use of a jack, shore up the vehicle on a safety seat,
2. Disconnect the wheel speed sensor joint of ABS control unit.
3. Turn every wheel at the speed by one turn per second and check each sensor. If the voltage value doesn’t
meet the requirements, replace the wheel speed sensor of ABS control unit.
Current value: 7.15—14.3 mA
Inspection of voltage waveform
1. Jack up the vehicle on a level ground by use of a jack, shore up with a safety bracket.
2. Disconnect the wheel speed sensor joint of ABS control unit.
3. Turn every wheel and check with an oscilloscope, whether the voltage of waveform is deformed of has
any noise. If there is any deformation or noise, check the rotor of ABS control unit sensor.

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 Anti-lock brake system (ABS control unit)

OBD
Fault diagnostic guide
ABS control unit
Foreword

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1. Understand the basic process of fault diagnostic for the correct operation.
2. Prior to take the operation steps for the fault diagnostic symptom, check the fault diagnostic first. Carry
out the inspection steps according to the fault diagnostic codes
Statement
When making the check or maintenance of ABS control unit, pay attention to the following points:
Even if the system is normal, the warning light of ABS control unit would be lit, this depends on the
installation and detailed work conditions.
Conditions where the
Cases where the warning light of ABS
warning light of ABS Control of ABS control unit
control unit is likely to lighten up
control unit goes off
When the front wheel of vehicle is
jacked up by a jack, or clamped or placed
on the roller of chassis, and the front
wheels run at the speed more than 20s
Turn the ignition switch
The parking handle is not completely
in the OFF position and
laid down during the drive in the vehicle If the ABS control unit is operating,
drive the vehicle at the
it will stop the control after the
There are scratches on the brake speed more than 15km/h
completion.
and confirm that the
The vehicle has been suddenly
operation is normal.
accelerated or decelerated.
L/R or front/rear tires are not identical
(the size, spokes, tire pressure, wear and
tires are differently labeled)
Continue to apply the control on the
ABS control unit until the battery
voltage decreased lower than 8V.
The battery voltage at the ignition end of The voltage of battery
control modular of ABS control unit is increased up to more If the speed exceeded 6km/h, the
below 10V. than10V. battery voltage decreases lower than
10V, the control modular of ABS
control unit will record the fault
codes.

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 Anti-lock brake system (ABS control unit)

Description of ABS control unit during the maintenance process

The ABS control unit is composed of the electric and mechanical parts. When the faults are diagnosed, it is
necessary to divide those faults into the electric system and hydraulic pressure unit.

1. Electric system fault

a. The ABS control unit modular has the fault diagnostic function. According to such function, the warning
light of ABS control unit will lighten up when there is a failure occurred in the electric system. At the
meantime, the previous and current faults can be recorded on the ABS control unit modular. This fault
diagnostic function is able to detect the faults not yet shown up during the regular inspection. After the
TBS terminal on the DLC is short-circuited with the grounding end, or connected with the SST, enabling
the ignition switch to turn in the ON position. In 5s, the saved fault codes will show up according to the
priority of presence. To find out the fault origin of ABS control unit, refer to the table of fault diagnostics.
If there has been the presence of some certain fault, it is now a normal case, and came about due to the
temporarily bad contact of harness. The control modular of ABS control unit remains in normal
communication. When tracing the reasons of faults, be careful not to damage the sensor elements.
b. After the repair, delete the fault codes saved in the modular in the ABS control unit. At the meantime, if
the parts associated with the ABC control unit have been replaced, confirm that the fault codes do not
exist any further after the replacement.

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c. After the wheel speed sensor of ABS control unit repaired or the ABS control unit replaced, even if the
ignition switch were turned in the ON position, the warning light of ABS control unit may be not go off.
At this moment, please drive the vehicle at the speed more than 15km/h, allowing the ABS control unit
system to carry out a dynamically self-check. Assure that the ABS control unit light has gone off and
then delete the fault codes.
d. If the relevant plugs of ABS control unit disconnected and the ignition switch turned in the ON position
during the repair, the control modular of ABS control unit will take it as an error and record it as a fault.
e. To protect the control modular of ABS control unit, prior to connect or disconnect the control modular
plug of ABS control unit, the ignition switch has to be turned in the OFF position. In order to protect the
terminal, the SST must be used when the tester terminal is connected with the control modular plug of
ABS control unit.

2. Faults in the hydraulic pressure unit

a. The faults of hydraulic pressure unit are similar wit those in the conventional brake system. it 必须 must
be determined whether the fault exists inside the component of ABS control unit or in the conventional
brake system;
b. The precision parts are contained in the hydraulic pressure component of ABS control unit. If foreign
materials are mixed inside, it may result in failures and hinder the ABS control unit from the operation.
As it is very difficult to localize the fault position, cares must be taken to avoid foreign substance from
ingress into the hydraulic pressure unit of ABS control unit, when the ABS control unit is under
maintenance (if the brake fluid is replaced or the pipeline removed).

Index of diagnostics
1. Sometimes, cases may exist, where there are no records of fault codes in the modular of ABS control unit
control while both the warning light and indicator light are lit.
In the following table are listed the faults with such phenomena and the fault symptoms, where, indicator
light doesn’t lighten up.
2. Confirm the fault and carry out the operation of fault diagnostics according to the suitable S/N.

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 Anti-lock brake system (ABS control unit)

S/N Symptom
1 Turn the ignition switch in the ON position, but the warning light of ABS control unit is not lit up
Turn the ignition switch in the ON position, the warning light of ABS control unit keeps lit for
2
more than 4s.
When parking or driving the vehicle, the warning light of ABS control unit is lit and won’t go off
3
until the ignition switch has been turned to the OFF position.
4 When parking or driving the vehicle, the warning light of ABS control unit flashes on
Although the warning light indication system of ABS control unit is normal, but faults really exist
5
in the system.

Diagnostic diagram
ABS control unit CM

Instrument component

Warning light circuit of ABS control unit

Battery

Charge system

CM power supply of ABS control unit

CM GND1 of ABS control unit

Conventional brake

HU

brake lines and chosen itinerary

Wheel speed sensor of ABS control unit

Tire size and pressure

Possible causes

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Fault diagnostic items

The ignition switch turned in the

ON position, but the warning light X X X
of ABS control unit is not lit.

The ignition switch turned in the

ON position, but the warning light
X X X X X
of ABS control unit keeps lit
within 4s.

When parking or driving the

vehicle, the warning light of ABS
control unit is lit and won’t go off X X X X
until the ignition switch has been
turned in the OFF position.

When parking or driving the

vehicle, the warning light of ABS X X X X X X
control unit flashes on

Although the warning light

indication system of ABS control
X X X
unit is normal, but faults really
exist in the system.

Troubleshooting

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 Anti-lock brake system (ABS control unit)

When the ignition switch is turned in the ON position, the alarm light of ABS control
1
unit is not lit
Tips of
The alarm light line of ABS control unit alarm light is short circuited to earth
troubleshooting
Steps Check items Operation
Confirm that no DTC saving exists. If
Yes any savings do exist, repair them and
Do other indicator lights lighten up when the go to the next step.
1
ignition switch is turned to the ON position？
Check and repair the PS circuit and
No
grounding line of instrument panel.
Does the alarm light of ABS control unit If the control modular of ABS control
lighten up when the control modular joint of Yes unit is short-circuited, replace the
2 control modular of ABS control unit
ABS control unit is disconnected and the
ignition switch turned on？ No Go to the next step
Check whether the harnesses between the ABS Yes Repair the fault part.
3 control unit control modular alarm light lead Check and repair the alarm light
and instrument are short circuited to earth？ No
circuit in the instrument

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The ignition switch is turned in the ON position, the alarm light of ABS control unit
2
keeps lit for more than 4s
ABS control unit detected the fault;
Tips of ABS control unit detected the too low of power voltage;
troubleshooting CM of ABS control unit doesn’t work;
The alarm light line of ABS control unit is circuit-broken.
Steps Test items Operation
Yes Go to the step 3
Whether the control modular joint of ABS
1 Connect the joint properly and go to
control unit is in good connection？ No
the next step
Poor joint contact in short time. Check
Whether the alarm light of ABS control unit Yes the modular joint and lead of ABS
2 goes off when it is lightened up in 4s after the control unit control
ignition switch is turned on？
No Go to the next step
Carry out the diagnostic check of fault codes. Carry out the inspection according to
Yes
See——Reappearance of Diagnostic Function, the DTC
3
ABS Control Unit/TCS, DTC Test, whether the
DTC has been recorded？ No Go to the next step

Yes Go to the next step

4 Whether the battery voltage is normal？
No Check the battery and charge system.
Whether the battery is normal, when the engine Yes to the next step
5
runs idle and has electric load？ No Check the charge system

Steps Test items Operation

P-39
 Anti-lock brake system (ABS control unit)

Disconnect the control modular joint of ABS Check and maintain the harnesses
control unit, connect the SST only at the harness Yes between the modular PS and
side of vehicle. Use the SST joint and connect grounding of ABS control unit
the lead of alarm light to the bodywork Check and repair the harness
6 grounding. break-circuit and the alarm light
Whether the alarm light of ABS control unit No circuit in the instrument between the
goes off when the ignition switch in the ON modular and alarm light of ABS
position turned. control unit

When parking or driving in the vehicle, the alarm light of ABS control unit is lightened
3
up and goes off until the ignition switch is turned in the OFF position.
The control modular of ABS control unit detected the faults, but the normal operation of
control modular of ABS control unit will be detected when the ignition switch is turned
Tips of on again;
troubleshooting The ABS control unit detected the low battery voltage, but it will detest that the control
modular of ABS control unit is in normal operation when the ignition switch is turned
on again,

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Steps Test items Operation
Carry out the DTC test. See—— OBD Carry out the inspection as per the
Yes
function, Check of ABS control unit/TCS, corresponding DTC.
1
Whether the DTC has been saved in the
memory？ No Go to the next step

Yes Go to the next step

2 Whether the battery voltage is normal？
No Check the battery and charge system.
Check and repair the harnesses
between the power lead of control
Whether the battery voltage is normal when Yes
3 modular of ABS control unit and
the engine runs idle and has electric load？ grounding 1
No Check charge system

When parking or driving in the vehicle, the alarm light of ABS control unit alarm light
4
flashes
There are intermittent break-circuit in the alarm light circuit of ABS control unit;
Tips of
troubleshooting The control modular of ABS control unit is repeatedly On and Off(power supply and
grounding wire etc are intermittently break-circuited);
Steps Test items Operation
Yes Go to the step 3
Whether the control modular joint of ABS
1 Connect properly the joint and go to
control unit is in good connection？ No
the next step
Intermittently poor contact,
Whether the alarm light of ABS control unit is Yes Check the joint box leadoff control
2 relit when starting the engine and driving the
modular in the ABS control unit.
vehicle with the alarm light On？
No Go to the next step

Steps Test items Operation

P-40
 Anti-lock brake system (ABS control unit)

Carry out the DTC test. Yes Check as per the corresponding DTC.
See——Reappearance of Diagnostic Function,
3
Test of ABS Control Unit/TCS and DTC No Go to the next step
Whether the DTC has been recorded？
Yes Go to the next step
4 Whether the battery voltage is normal？
No Check the battery and charge system
Whether the battery is normal when the engine Yes to the next step
5
runs idle and has electric load？ No Check the charge system
Check and repair the power supply of
Disconnect the control modular joint of ABS Yes ABS control unit modular and
control unit, connect the SST only at the harness grounding 1
side of vehicle. Use the SST joint and connect
the lead of alarm light to the bodywork Check and repair
6 grounding. The break-circuit occurred in the
Whether the alarm light of ABS control unit No connection harnesses between the
goes off when the ignition switch in the ON alarm light circuits of ABS control
position turned. unit modular, alarm light and
instrument panel

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Although the alarm light of ABS control unit is common in the system, but there are in
5
fact, the faults in the system
Tips of
There are mechanical faults in the system.
troubleshooting
Steps Test items Operation
Carry out the inspection of DTC. Yes Check as per the corresponding DTC.
See——Reappearance of Diagnostic Function,
1
Test of ABS Control Unit/TCS and DTC No Go to the next step
Whether the DTC has been recorded？
Yes Check the conventional brake system
When the wheels don’t rotate, replace
Carry out the “Inspection of Hydraulic Pressure the hydraulic pressure unit of ABS
Unit System of ABS Control Unit “ control unit;
2 See——ABS control unit, Check of Hydraulic When the wheels run, but in a wrong
Pressure Unit of ABS Control Unit. No
sequence.
Whether the check result is normal？ Check the piping of hydraulic
pressure unit of ABS control unit on
the brake oil lines.

Analysis of fault cases

P-41
 Anti-lock brake system (ABS control unit)

Potential failure
DTC DTC(16hex) Description of DTC
symptom
Left front wheel speed sensor open-circuited or
C0032 0x4032 0100
short-circuited
C0031 0x4031 1000 Left front wheel speed sensor in intermittent operation
Right front wheel speed sensor open-circuited or
C0035 0x4035 0100
short-circuited
Right front wheel speed sensor in intermittent
C0034 0x4034 1000
operation
Left rear wheel speed sensor open-circuited or
C0038 0x4038 0100
short-circuited
C0037 0x4037 1000 Left rear wheel speed sensor n intermittent operation
Right rear wheel speed sensor open-circuited or
C003B 0x403B 0100
short-circuited
C003A 0x403A 1000 Right rear wheel speed sensor in intermittent operation

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In terms of the faults of wheel speed sensor, they are caused in general by the following reasons:
Wheel speed sensor;
Wheel speed sensor harness;
Harness connector;
Gear rim of ABS control unit;
ECU joint;
After the fault codes deleted, accelerate the speed up to ca.15km/h and the ABS control unit runs in
sound state, the ABS control unit shouldn’t be replaced.

Faults of wheel speed sensor

Faults Possible fault area
1. Wheel speed sensor;
2. Wrong connection of wheel speed sensor;
3. Interference on the signal of wheel speed sensor;
Wheel speed sensor or its signal fault. 4. Too large clearance between the wheel speed sensor and gear
rim(the mounting bolt of wheel speed sensor loosened and
the sensor displaced due to the vibration);
5. Wheel speed sensor and holder corroded;
6. Fault of gear rim(dirt, teeth on the gear rim damaged)
1. The connector defected, dirty or wet;
2. The connection and plugging of wheel speed sensor loosened
Connection fault of wheel speed sensor or broken;
3. The sensor line short-circuited with the grounding;
4. The isolation layer of sensor connection damaged
The wheel speed sensor tests the wheel speed and feeds the relevant signal to the ECU of ABS control
unit. These signals are designated to control the work of ABS control unit.
Faults of solenoid

P-42
 Anti-lock brake system (ABS control unit)

Potential failure
DTC DTC(16hex) Description of DTC
symptom
C1095 0x5095 0100 Fault of solenoid
C0010 0x4010 0100 Fault of left front inlet valve
C0011 0x4011 0100 Fault of left front outlet valve
C0014 0x4014 0100 Fault of right front inlet valve
C0015 0x4015 0100 Fault of right front outlet valve
C0018 0x4018 0100 Fault of left rear inlet valve

Faults Setting conditions Possible fault area

1. Start the corresponding solenoid, but no
feedback;
2. After the ignition switch turned on, the ECU of
ABS control unit detected the permanent or
intermittent short-circuit of the corresponding
solenoid to the power supply or grounding; 1. Faults in the oil line in the ABS
control unit with the hydraulic

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3. During the drive in the vehicle, the fault in the
pressure regulator: braking
Solenoid fault solenoid or its connection is detected;
circuit; electricity;
-- The vehicle remains in static state with the
2. Hydraulic pressure /mechanical
brake pedal not depressed.
faults.
-- The speed is ca.15km/h when the brake pedal
stepped down.
4. In all conditions, there are faults in the oil line
in the ABS control unit with the hydraulic
pressure regulator.

The ECU of ABS control unit controls the solenoid operation through the control of the grounding of
each solenoid, to regulate the braking pressure of every brake loop.

Faults in the reflux pump/motor

Potential failure
DTC DTC(16hex) Description of DTC
symptom
C0020 0x4020 0100 The reflux pump doesn’t work (motor circuit)

Faults Causes of failures Possible fault area

1. The “motor circuit of reflux
pump “in the ABS control unit
1. After the motor relay of reflux pump has been 2. The motor relay circuit of reflux
operating for 60ms, the monitoring on the pump break circuited
reflux pump detected no voltage signal;
3. Fault in the motor relay of reflux
2. The motor relay of reflux pump failed to work, pump;
Reflux
the monitoring on the reflux pump has
pump/motor 4. Fault in the motor connection of
detected that the voltage exceeded 2.5s
reflux pump;
3. The motor relay of reflux pump stopped
5. Poor grounding;
working, the monitoring on the reflux pump
detected that the voltage did not drop down. 6. Poor power supply
7. Fault in the motor of reflux
pump

In the stage of pressure reduction of ABS control unit: the reflux pump is operating, pumping the

P-43
 Anti-lock brake system (ABS control unit)

brake fluid on the brake slave-pump of blocked wheel back to the line of brake master-pump and
decrease the pressure of brake slave-pump.
In the stage of EBD pressure reduction: Brake fluid flown back after stored in the accumulator, but, if
the accumulator has been filled up with the brake fluid, and the deceleration of rear wheels are still
faster than the front wheels, the ECU of ABS control unit controls the action of reflux pump, and pump
back the excessive brake fluid into the circuit of brake master-pump.

Faults of brake light switch

Faults Causes of failures Possible fault area
1. Brake light switch
There are open-circuits or too high resistance in the 2. Circuit of brake light switch
following lines: 3. Plugging-in of brake light
Brake switch 1. Signal circuit of brake light switch, switch;
2. Grounding circuit of brake light 4. ABS control unit grounding;
3. Brake light 5. ABS control unit with
hydraulic pressure regulator;

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The brake light switch is a constant open switch. When the brake pedal stepped down, this switch is
close. The brake light switch will provide the brake light signal circuit (+BLS) with the signal voltage.
The ECU of ABS control unit supervises the signal voltage of brake light switch, so as to confirm the
coupling time of brake and test the circuit of brake light switch.
Recommendation: Check the harness of brake light switch.
The ABS control unit shall not be replaced.

ECU faults
Potential failure
DTC DTC(16 hex) Description of DTC
symptom
C1900 0x5900 0100 ECU voltage too high
C1901 0x5901 0100 ECU voltage too low
C1000 0x5000 0100 HW fault in the ECU

Recommendation: Check the battery and the level of voltage.

The ABS control unit shall not be replaced.

P-44