YUAN Service Manual

ESP System

Contents

1. NOTE..............................................................................................................................................3
1.1 Maintenance Note...............................................................................................................3
2. MALFUNCTION DIAGNOSIS PROCEDURE...............................................................................6
3. TROUBLE ANALYSIS TABLE PROVIDED BY CLIENT.............................................................7
3.1 Trouble Analysis Table Provided by Client.......................................................................7
4. DIAGNOSTIC TEST.......................................................................................................................8
4.1 Preliminary Check...............................................................................................................8
5. ESP 9 SYSTEM INTRODUCTION..............................................................................................11
5.1 Composition of ESP System............................................................................................11
5.2 ESP 9 Hydraulic Dagram..................................................................................................12
5.3 ESP 9 ECU Interface Circuit...............................................................................................13
6. MALFUNCTION DIAGNOSIS......................................................................................................15
6.1 Malfunction Repair without DTC.........................................................................................15
6.2 Occasional Malfunction Repair.......................................................................................15
7. DTC LIST......................................................................................................................................16
8. MALFUNCTION SYMPTOM........................................................................................................19
8.1 Malfunction Symptom Table............................................................................................19
8.2 Intermittent Malfunction Diagnosis Table......................................................................20
9. DTC DIAGNOSIS.........................................................................................................................21
9.1 Power Supply Voltage is too High/Low...............................................................................21
9.2 Electromagnetic Valve and Valve Bank Relay Failure........................................................21
9.3 Electromagnetic Valve and Valve Bank Relay Failure........................................................22
9.4 Wheel Speed Sensor Circuit Failure...................................................................................23
9.5 Wheel Speed Sensor Signal Failure...................................................................................24
9.6 ESP ECU Fault...................................................................................................................25
9.7 CAN Bus Failure.................................................................................................................25
9.8 Pressure Sensor Failure.....................................................................................................26
9.9 Steering Wheel Angle Sensor Failure.................................................................................26
9.10 Yaw Rate Sensor (Integrated Sensor) Failure..................................................................27
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 YUAN Service Manual

9.11 ECM Failure......................................................................................................................28

9.12 Gateway Failure................................................................................................................28
9.13 EPB Failure.......................................................................................................................29
9.14 ESP PATA Switch Failure..................................................................................................29
9.15 ESP Configuration Information Failure.............................................................................30
9.16 Brake Lamp Switch (BLS) Fault........................................................................................30
9.17 Abnormal Operation of ESP..............................................................................................31
9.18 Clutch Signal Abnormal....................................................................................................31
9.19 Reverse Gear Signal Abnormal........................................................................................32
10. REMOVAL AND INSTALLATION..............................................................................................33
10.1 Removal Steps of ESP Assembly.....................................................................................33
10.2 Installation Steps of ESP Assembly..................................................................................33
10.3 Exhaust Description..........................................................................................................33
10.4 Integrated Sensor Calibration Instructions (ESP9i System).............................................33
11. SERVICE TECHNICAL PARAMETERS...................................................................................35
11.1 General Technical Parameters.........................................................................................35
11. 2 Torque (Unit: N · M)..........................................................................................................35

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1. Note
1.1 Maintenance Note
ESP (Electronic Stability Program) is a safety-related component. So during its service and
diagnosis, the following diagnosis considerations must be followed in addition to the general safety
and preventive measures.
(a) ESP system must only be repaired by
professionally trained technicians with
maintenance skills. Only the original parts of
manufacturer can be used for replacement.

(b) Prior to the diagnosis of ESP system, any fault

of the basic brake system must be eliminated first.
For example:
Brake system noise.
Brake pedal hard to push down.
Vibration of the brake pedal or vehicle during
conventional braking.
Braking deviation.
Fault in parking brake system.

(c) ESP assembly (refers to ESP ECU and the

hydraulic regulator assembly, excluding the
accessories such as brake lines, sensors, etc.)
can only be replaced as a whole. It must not be
dismantled or partially replaced/interchanged.
Bosch does not provide individual spare parts,
does not cover repairs of ESP disassembled by
persons other than Bosch, and assumes no
responsibility for any adverse consequences due
to unauthorized dismantling or partial
replacement/interchange of ESP hydraulic
regulator.
(d) The following two cases indicate that the ESP
system detects malfunction:
①Warning lamp remains lit after the ignition
switch is turned on.
②Warning lamp remains lit in the driving
process.
At this moment, the driver can perform normal
braking, but he should reduce the braking force to
prevent the wheels from locking. So drive
carefully when the warning lamp illuminates. You
are recommended to immediately repair the ESP

3
 system at an authorized service shop to prevent
greater failure and accidents.

(e) Pay attention to the following while connecting

ESP and sensor wiring harness:
Turn off the ignition switch before unplugging ESP
wiring harness and sensor wire harness.
Make sure the connectors are dry and clean, and
avoid any foreign objects entering.
ESP wire harness must be installed in position in
horizontal and vertical directions, so as not to
damage the connectors.

(f) Make sure to properly connect the ESP brake

lines. ESP ECU cannot determine whether the
braking lines are correctly connected and it will
not execute fault protection. Incorrect connection
may cause serious accidents.
The mark on the ESP hydraulic controller may
vary with the place of manufacturing:
MC1: connected to brake line 1 of the brake
master cylinder;
MC2: connected to brake line 2 of the brake
master cylinder;
FL: connected to the brake lines of front left
wheel brake cylinder;
FR: connected to the brake lines of front right
brake wheel cylinder;
RL: connected to the brake lines of rear left
brake wheel cylinder;
RR: connected to the brake lines of rear right
brake wheel cylinder.
(g) ESP generates noise under one of following
circumstances:
After vehicle power is turned on or the engine is
started, it will produce a short buzz sound, which
is a normal phenomenon of ESP self-test. In
addition, when the car accelerates to about
15km/h, it will also produce a short buzz sound,

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 which is a normal phenomenon of ABS dynamic
self-test.
ESP will produce sound during normal working
with main causes as follows:
1) Sound generated by the action of motor,
electromagnetic valve and reflux pump in the ESP
hydraulic unit.
2) Sound caused by the brake pedal rebound.
3) Sound caused by impact of the suspension and
body during emergency braking.

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2. Malfunction diagnosis procedure
Malfunction diagnosis procedure
1. The car enters the vehicle repair shop

2 Customer complaint analysis

3 Read DTC
DTC Go to Step 4

No DTC
Go to Step 6

4. Record DTC and then clear the malfunction memory.

5. Verify and reproduce the malfunction: re-ignite and start the vehicle and accelerate it to
15kph, then read the DTC again.
DTC
Current DTC. Go to Step 7

No DTC
Historical DTC. Go to Step
8
6. Service without DTC, go to step 9.

7. Eliminate faults according to the DTC list and go to step 9.

8 Service occasional malfunction, go to step 9.

9. Verify malfunction has been eliminated.

10. Prevent recurrence of malfunction. Finish

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3. Trouble Analysis Table Provided by Client

3.1 Trouble Analysis Table Provided by Client

ESP Checklist
Quality inspector
Owner Vehicle license number
name Model
Contact
Chassis number
number
Arrival / / Odometer km

Date of
/ /
Malfunction occurrence
scenario Occurrence
口 often 口 occasionally ( time(s) / day)
frequency

口 Poor operation of ESP 口 ESP does not work

口 Poor operation of EBD 口 EBD does not work

Phenomenon ESP warning light

does not work 口continuously illuminated 口 off
normally
EBD warning light
does not work 口continuously illuminated 口 off
normally

口Normal DTC 口Current DTC(Code: )

First time
口 Historic DTC (Code: )
Check the
fault:
Second 口Normal DTC 口Current DTC(Code: )
time 口 Historic DTC (Code: )

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4. Diagnostic test
4.1 Preliminary check
Before diagnosis of the ESP system, first check components which may cause the fault of the ESP
system and parts which are easily accessible. Further diagnosis is unnecessary if faults can be
determined quickly by visual inspection of the outward appearance.
(a) Make sure that only tires and wheels of
recommended sizes are installed on the
vehicle. The tread and depth of tires of same
axle must be the same.
Original standard tires: 205/60R16 92V
205/50R17 93W
225/45R18 95V

(b) Check the hydraulic regulator, brake lines

and the connector for leaks.

(c) Check the fuses of ESP system to make

sure that the fuse is not blown and its model is
correct.
ESP system has three fuses as follows:
pump motor fuse (40A)
electromagnetic valve fuse (25A)
ECU fuse (5A)

(d) Make sure that the battery is fully charged

and check its voltage.
(e) Check the battery connections for corrosion
or loosen posts.
The normal operating voltage range of the ESP
system is 9.3V-16.8V.

(f) Check whether the ground contact point of

ESP grounding wiring is loose and whether the
ground position has been moved.

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 (g) ESP grounding wire must be completely
sealed to prevent water and moisture from
penetrating the connector of ESP ECU through
capillary (siphon) effect via the harness pore
canal, thereby causing functional failure.
Measures: apply sealant to the exposed end of
the wire harness and use a heat-shrinkable
tube envelope

(h) Carry out visual inspection and appearance

inspection for the following electrical
components:
Fuse ① whether the pin and wiring harness of ESP
components are properly connected, pinched
or cut.
② whether the harness wiring is very close to
high voltage or high current devices, such as:
Fuse-link High-voltage ignition components
Motors and generators
Stereo amplifier installed after sales
Important note: High voltage or high current
device may cause the circuit to make induced
noise which will interfere with normal operation
of the circuit

③Whether connector of ESP related

components is connected poorly and pins are
fully inserted into the connector shell.
④ESP component is sensitive to
electromagnetic interference (EMl). If you
suspect an intermittent fault, check whether the
anti-theft protection device, lamp or mobile
phones installed after sales are wrongly
installed.

(g) ESP is an active safety system. Its main

function is to maximize the use of ground
adhesion to maintain the car's maneuverability
and driving stability. However, if the driving
condition exceeds the physical limits or the car
travels at a high speed on wet and slippery
roads, ESP cannot fully prevent the car from
slipping.

(h) If the ESP has too much noise, it may be

caused by the following factors:
Fixation between ESP assembly and the
bracket becomes loose.
Fixation between ESP bracket and the body
Apply sealant to the exposed end of the
wire harness and use a heat-shrinkable becomes loose
tube envelope Plastic washer of ESP bracket is missing or
damaged.

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 Ignition coil
/Distributor/
Spark plug
Toothed ring

Generator

Wheel speed sensor

Electromagnetic
interference (EMl)

Electromagnetic
interference (EMl)

Hydroplaning

5. ESP 9 system introduction

5.1 Configuration of ESP system
As shown below, ESP 9 consists of the hydraulic module with ECU and the respective sensors.

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① ESP hydraulic regulation module with ECU
② Wheel speed sensor
③ Steering angle sensor
④ Yaw rate sensor (this model uses ESP9i system, yaw rate sensor is integrated in the ESP module)
⑤ Communication with the engine management system

ESP detects the driver's intention: through the steering wheel position, wheel speed, throttle position
and brake pressure, ECU can recognize the driver's intention.
ESP identifies the vehicle condition: with yaw rate and lateral force (acceleration), ECU calculates
and identifies the vehicle condition.
ESP intervenes and assists in steering by braking: ECU calculates the control required to maintain
the stability and the fast braking of respective individual wheel with the hydraulic module. In addition,
EPS also communicates with the engine management system to reduce the engine torque output.

Steering angle sensor

1. Steering angle sensor can be a single component or integrated in ESP system;
2. Function: measure the orientation angle and output it in standard CAN signal.
Note: The steering angle sensor should be calibrated after installed in the car to determine the
middle position of the steering wheel.

5.2 ESP 9 Hydraulic diagram

The brake system uses X arrangement, as shown in the figure below. ESP 9 hydraulic regulator
includes a motor, two reflux pumps, two accumulators, a pressure sensor and twelve electromagnetic
valves.

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English abbreviations in the figure are explained below:
MC1 The first loop of the brake master cylinder FLAV Liquid outlet valve of front left wheel
MC2 The second loop of the brake master FREV Liquid inlet valve of front right wheel
cylinder
M Motor FRAV Liquid outlet valve of front right
wheel
RP1 Reflux pump 1 RLEV Liquid inlet valve of rear left wheel
RP2 Reflux pump 2 RLAV Liquid outlet valve of rear left wheel
A1 Accumulator 1 RRE Liquid inlet valve of rear right wheel
V
A2 Accumulator 2 RRA Liquid outlet valve of rear right
V wheel
FL Front left wheel HSV1 High-pressure valve
FR Front right wheel HSV2 High-pressure valve
RL Rear left wheel USV1 Pilot valve
RR Rear right wheel USV2 Pilot valve
FLE Liquid inlet valve of front left wheel P/U Pressure sensor
V

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5.3 ESP 9 ECU interface circuit

5.3.1 ESP 9 ECU circuit diagram

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5.3. 2 ESP 9 ECU pin definition
Pin Function Pin Function
1 Motor positive terminal 20 Undefined
2 wheel speed sensor output (Right front) 21 Undefined
3 EBD Warning lamp (reserved) 22 Undefined
4 Wheel speed sensor signal terminal (front 23 Undefined
right)
5 wheel speed sensor output (Right front) 24 ESP off indicator (reserved)
6 Diagnosis line K(reserved) 25 Valve relay power terminal
7 Undefined 26 CAN_H
8 Wheel speed sensor signal terminal (front 27 ABS Warning lamp ( reserved)
left)
9 Gear signal(reserved) 28 ECU power supply terminal (ignition
power wiring)
10 Speed output (reserved) 29 Wheel speed sensor signal terminal (rear
right)
11 Undefined 30 Brake lamp switch
12 ESP off switch 31 Wheel speed sensor power supply
terminal (rear left)
13 Ground terminal of the motor 32 Undefined
14 CAN_L 33 ESP Warning lamp (reserved)
15 Clutch signal (reserved) 34 Undefined
16 Wheel speed sensor power supply terminal 35 Undefined
(front right)
17 Wheel speed sensor power supply terminal 36 Undefined
(rear right)
18 Wheel speed sensor signal terminal (rear 37 Undefined
left)
19 Wheel speed sensor signal terminal (front 38 ECU ground terminal
left)

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6. Malfunction diagnosis
6.1 Malfunction repair without DTC
If the brake system has malfunction, but no DTC is stored in ESP, this is referred to as
malfunction without DTC. Malfunctions without DTC are generally caused by basic brake system
failure. For example:
Brake fluid leakage (may cause soft brake, extended brake pedal travel or even brake failure in
serious cases).
Using inferior brake fluid (this will corrode the brake lines and internal components of ESP
hydraulic regulation module or even cause brake failure).
Air in the brake lines (may cause soft brake or even brake failure).
Clogging of the brake lines (may cause hard brake or even brake failure)
Excessive wear of the brake disc (may cause soft brake and extended brake pedal travel)
Booster failure (may cause soft or hard brake, extended brake pedal travel or even brake failure
in serious cases)
Brake pipeline connection error (may cause ESP performance degradation, fishtailing or long
braking distance. For the correct installation method, refer to the identifications near the oil hole in
the ESP hydraulic regulation module: MC1 represents master cylinder 1; MC2 represents master
cylinder 2; FL represents the front left wheel cylinder tubing; FR represents the front right wheel
cylinder tubing; RL represents the rear left wheel cylinder tubing; RR represents the rear right wheel
cylinder tubing).
Note: No power supply or abnormal power interruption of ESP can cause continuous illumination of
ABS and ESP warning indicator without DTC.
Troubleshooting advice: Check components related to the problem and eliminate faults in
accordance with the vehicle service manual.
6.2 Occasional Malfunction Repair
In an electronic system, the electric circuit and I/O signals may have transient poor contact, resulting
in occasional malfunction. Sometimes the cause of failure may disappear automatically, so it is not
easy to find out the problem. When occasional malfunction occurs, try to simulate the malfunction in
the following method to check whether the malfunction recurs.
No. Possible causes Malfunction simulation Remarks
1 When shock is Gently rock ESP ECU If the harness is twisted off or
probably the main connectors up and down, left broken due to excessive stretching,
reason, and right; then the parts must be replaced;
Gently rock the harness up When the car is running, the
and down, left and right harness of wheel speed sensor
Gently rock sensors up and may have momentary open/short
down, left and right circuit with the up and down
Gently rock other moving parts movement of the suspension
(such as wheel bearings) system.
Therefore, vehicle driving test must
be carried out when checking
sensor harness.
2 When temperature is Heat the suspected faulty parts
probably the main with a dryer; Check for cold
reason, welding with cold spray
3 When excessive high Turn on switches of all electric
load electricity apparatus, including the
consumption is headlights and wiper to make
probably the main power supply of the car

15
 reason, operate under high load

If the fault is not reproduced, diagnosis service should wait until the next time the fault occurs. In
general, occasional fault will gradually evolve into reproducible and will not disappear automatically.

7. DTC list
Note:
Switch to OFF position before removing any part.
Description:
Read DTC with the diagnostic tester.
If malfunction is not detected while checking the components, check the ECU ESP hydraulic
pressure regulator and its ground point/power cord.
If DTC is memorized, check the circuit indicated by the DTC. Refer to corresponding sections for
specific maintenance steps for each DTC code.
If two or more DTCs are memorized, first check the DTC and circuit related to the fault.

DTC Inspection item Possible fault zone Page

Front left wheel speed sensor

Front left wheel speed sensor
C003108 Circuit of front left wheel speed sensor
signal failure
Tooth ring of front left wheel speed sensor
Front left wheel speed sensor
Front left wheel speed sensor
C003204 Circuit of front left wheel speed sensor
circuit failure
Tooth ring of front left wheel speed sensor
Front right wheel speed sensor
Front right wheel speed sensor
C003408 Front right wheel speed sensor circuit
signal failure
Tooth ring of front right wheel speed sensor
Front right wheel speed sensor
Front right wheel speed sensor
C003504 Front right wheel speed circuit
circuit failure
Tooth ring of front right wheel speed sensor
Rear left wheel speed sensor
Rear left wheel speed sensor
C003708 Circuit of rear left wheel speed sensor
signal failure
Tooth ring of rear left wheel speed sensor
Rear left wheel speed sensor
Rear left wheel speed sensor
C003804 Circuit of rear left wheel speed sensor
circuit failure
Tooth ring of rear left wheel speed sensor
Rear right wheel speed sensor
Rear right wheel speed sensor
C003A08 Rear right wheel speed sensor circuit
signal failure
Tooth ring of rear right wheel speed sensor
Rear right wheel speed sensor
Rear right wheel speed sensor
C003B04 Rear right wheel speed sensor circuit
circuit failure
Tooth ring of rear right wheel speed sensor
Hydraulic regulator front left liquid
C001004 ESP hydraulic regulator with ECU
inlet valve failure
Hydraulic regulator front left liquid
C001104 ESP hydraulic regulator with ECU
outlet valve failure
Hydraulic regulator front right
C001404 ESP hydraulic regulator with ECU
liquid inlet valve failure
Hydraulic regulator front right
C001504 ESP hydraulic regulator with ECU
liquid outlet valve failure
Hydraulic regulator rear left liquid
C001804 ESP hydraulic regulator with ECU
inlet valve failure

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 DTC Inspection item Possible fault zone Page

Hydraulic regulator rear left liquid

C001904 ESP hydraulic regulator with ECU
outlet valve failure
Hydraulic regulator rear right
C001C04 ESP hydraulic regulator with ECU
liquid inlet valve failure
Hydraulic regulator rear right
C001D04 ESP hydraulic regulator with ECU
liquid outlet valve failure
ESP hydraulic regulator with ECU
Motor failure: the motor cannot
C002004 ESP hydraulic regulator ground/power, with
run or cannot be stopped
ECU
ESP hydraulic regulator with ECU
Electromagnetic valve relay circuit
C012104 ESP hydraulic regulator ground/power, with
failure
ECU
Wheel speed sensor
C024501 Wheel speed sensor failure Circuit of wheel speed sensor
Tooth ring of wheel speed sensor
Battery
Power and electrical ground of ESP
C055000 ESP ECU fault
hydraulic regulator with ECU
ESP hydraulic regulator with ECU
Battery
Power and electrical ground of ESP
C080001 Low voltage fault
hydraulic regulator with ECU
ESP hydraulic regulator with ECU
Battery
ESP hydraulic regulator power and electrical
C080002 Over voltage fault
ground, with ECU
ESP hydraulic regulator with ECU
C000104 Loop control valve 1 failure ESP hydraulic regulator with ECU
C000204 Loop control valve 2 failure ESP hydraulic regulator with ECU
C000304 High voltage switch valve 1 failure ESP hydraulic regulator with ECU
C000404 High voltage switch valve 2 failure ESP hydraulic regulator with ECU
C100104 CAN hardware failure ESP ECU
U100004 CAN Bus Off Gateway controller
Common valve failure
C007204 ESP hydraulic regulator with ECU
(overheating protection)
C004601 Pressure sensor failure ESP hydraulic regulator with ECU
SAS (angle sensor) CAN
U012604 Angle sensor wiring
Communication timeout
Angle sensor wiring
U012608 SAS CAN data destroyed
Angle sensor
Angle sensor
C046008 SAS signal failure
Angle sensor wiring
Angle sensor calibration error or Angle sensor wiring
C106600
not calibrated Angle sensor
Transverse acceleration sensor
C006108 ESP hydraulic regulator with ECU
signal failure
Longitudinal acceleration sensor
C006208 ESP hydraulic regulator with ECU
signal failure
C006308 Yaw rate sensor signal failure ESP hydraulic regulator with ECU
Integrated inertial sensor failure
C019604 (hardware, temperature, range, ESP hydraulic regulator with ECU
internal fault)

17
 DTC Inspection item Possible fault zone Page

Integrated inertial sensor not

C00A800 ESP hydraulic regulator with ECU
calibrated or calibration error
ECM module and wiring
U010004 ECM Communication timeout
ESP ECU and its wiring
U010008 ECM CAN data destroyed ECM module
U014004 Gateway communication timeout Gateway controller wiring
U014008 Gateway data destroyed Gateway controller
C004C04 ESP switch failure Switch and switch circuit
C121208 Variable code fault ESP hydraulic regulator with ECU
Brake pedal switch wiring, brake pedal
C004008 Brake pedal switch signal failure
switch
Instrument
C008208 Braking system failure indication
ESP ECU wiring
C108008 Clutch signal failure (HHC) Clutch switch and wiring
Reverse gear switch signal failure
C108C08 Reverse gear switch and wiring
(HHC)
Missing communication with gear
U100100 DCT module and wiring
position controller (DCT)
U010104 Missing communication with TCU TCU module and wiring
Received erroneous data from
U010108 TCU module and wiring
TCU
U100304 EPB CAN communication timeout EPB module and wiring
U100308 Abnormal data from EPB EPB module and wiring
C040008 EPB signal error EPB module and wiring

18
8. Malfunction symptom
8.1 Malfunction symptom table
If no DTC is saved, but malfunction still occurs, check the circuit of each malfunction in the sequence
shown in the table below and go to corresponding pages for diagnosis.
Note:
 Before servicing ESP, make sure the normal braking system is working properly.
 To replace the ECU ESP hydraulic regulator, sensor or other parts, turn OFF the ignition switch
first.

Malfunction Related
Area to check
symptom troubleshooting pages
Check item 1 ~ 4 below. If found nothing wrong but the
malfunction persists, replace the ECU ESP hydraulic
regulator: 10
1. Read DTC and ensure that there is no malfunction
ESP does not memory.
work 2. Start button power UZ (pin 32) circuit. 37
3. Circuit of wheel speed sensor. 30, 42
4. Check ESP with the diagnostic tester. If abnormality is
22
detected, check whether the brake lines leak.
Check items 1 ~ 5 below. If found nothing wrong but the
malfunction persists, replace the ECU ESP hydraulic
regulator: 10
1. Read DTC and ensure that there is no malfunction
memory.
ESP works 2. Circuit of wheel speed sensor 30, 42
poorly 3. Check ESP with the diagnostic tester. If abnormality is
6
detected, check whether the brake lines leak.
4. Use the diagnostic tester to read "Hydraulic regulator
11
filling state."
5. Make sure that the mounting bracket is fixed properly
(this will decrease driving comfort).
ESP warning 1. ESP warning light circuit. 27, 37
light does not 2. ESP hydraulic regulator with ECU. 60
work normally 3. Battery voltage is insufficient 62
Check items 1 ~ 3 below. If found nothing wrong but the
malfunction persists, replace the ECU ESP hydraulic
regulator: 37
DTC cannot be [Link] ESP hydraulic regulator ground wiring and power
read cord
2. ECU ESP hydraulic pressure regulator DIAGK (pin
37
17) line.
[Link] tester

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8.2 Intermittent malfunction diagnosis table

Instruction:
It is referred to as intermittent malfunction for one of following circumstances:
 Malfunction does not always occur:
 Malfunction cannot be reproduced;
 There is no current DTC, but the historic DTC is memorized.

Check Operation
4.1. First carry out “Preliminary check”.
· Collect information on the causes of intermittent malfunction from the customer, such as:
·Vehicle speed range when malfunction occurs
·Did the malfunction occur when using aftermarket electrical devices?
·Does the malfunction occur when the car travels on rugged or slippery roads?
·If wheel speed sensor failure occurs only when the car travels on wet and slippery roads
Preliminary check whether water enters into the wheel speed sensor circuit. If no DTC appears, carry out the
following operations to simulate the effect of wet and slippery roads:
1. Dissolve two teaspoons of salt in 35 ml of water.
2. Spray the saline water onto suspected locations.
3. Test the vehicle under a variety of road conditions.
4. Accelerate the car to over 40km/h for at least 30 seconds.
5. If the suspected wheel speed sensor is set with the current DTC, see the diagnosis table for
corresponding DTC.
Use the diagnostic tester to detect the intermittent malfunction as follows:
· Fiddle with harness and connectors of suspected ESP components, at the same time observe
the data flow of the circuit on the diagnostic tester. If the reading of the diagnostic tester
fluctuates under this operation, then check whether the wiring is loose.
Check with the · Test the vehicle under the road conditions where the intermittent malfunction occurs. At the
diagnostic tester same time, allow the assistant to observe suspected operation parameters on the diagnostic
tester.
· When a fault occurs, capture and store data in snapshot mode. Stored data can be played at a
slow speed to help diagnosis. An oscilloscope can also be used for signal detection.
· Use the element test function of the diagnostic tester to test the operation of suspected ESP
components.
Following circumstances may cause intermittent illumination of warning indicator without setting
DTC.
· Electromagnetic interference (EMl) caused by faulty elements (e.g.: relay).
· The electrical equipment installed after sales is abnormal or installation position is wrong, such
as:
·Mobile phone
Warning indicator
· Anti-theft alarm system
·Lamp
· Radio equipment
· Audio amplifiers
· Alarm indicator circuit intermittently short to ground.
ECU ESP hydraulic regulator/instrument ground point loosens
· Rotation speed is low.
· Visually inspect the wheel speed sensor and magnetic ring for loosening, damage, foreign
objects and incorrect installation. Replace the damaged parts and remove any foreign objects or
fix the loose parts.
Wheel speed
· Check whether the layout of wire harness of the front wheel speed sensor is correct. Make sure
sensor
that the front wheel speed sensor harness is not close to the distributor.
· With the help of an assistant, monitor the wheel speed sensor data displayed on the diagnostic
tester and conduct road test. Check whether the wheel speed sensor shows abnormal speed
range.
Additional test · Check electrical equipment installed after sales is correct, such as:
·Mobile phone
· Anti-theft alarm system
·Lamp
· Radio equipment
·Stereo amplifier
· Check for faulty elements (e.g.: when relay or solenoid conducts electricity) that may cause
electromagnetic interference (EMl).
·Relay or solenoid conduction test includes testing clamping diodes or resistance of the air
conditioning compressor clutch and certain relays.

20
 After relay or solenoid is energized, test if the bridge rectifier malfunctions, and make the A/C
noise enter into the ECU circuit.

9. DTC diagnosis
9.1 Power Supply Voltage is too High/Low
DTC: C080001, C080002

Conditions for setting malfunction:

When the power supply voltage of ECU satisfies one of the following conditions, this malfunction
occurs:
(1) The power voltage is lower than 4.5V when the car is powered initially.
(2) The ignition switch is in ON position, and the voltage is lower than 7.7V or higher than 16.8V.
(3) The vehicle speed is higher than 6km/h, and the voltage is between 7.7V and 9.2V.

Possible causes:
(1) The battery voltage is too high or too low.
(2) ECU damage.

Diagnostic steps:
Ste Operation Yes No.
p
1. Is a preliminary check carried out? Perform Carry out
step 2 “Preliminary
check”
2. Measure the voltage of ECU power supply pins, check Perform Perform step 3
connectors, wiring harnesses and ground wire. Is a fault found step 4
and eliminated? See the circuit diagram for pin definition.
3. Carry out cross-validation for ESP. If ECU breakdown is Perform --
ascertained, replace ESP. Is the fault eliminated? step 4
4. Conduct diagnosis again to verify recurrence of fault? -- Diagnosis is
finished

9.2 Electromagnetic Valve and Valve Bank Relay Failure

DTC: C001004, C001104, C001404, C001504, C001804, C001904, C001C04, C001D04, C000104,
C000204, C000304, C000404, C012104, C007204

Conditions for setting malfunction:

(1) Valve power failure. (Short circuit of power supply to ground or open circuit)
(2) Electromagnetic valve temperature is too high. (Overheating protection)
(3) Short circuit of 5 or more electromagnetic valves. (Fuses)
(4) Actuate the respective electromagnetic valve, but there is no feedback.
(5) The electromagnetic valve itself is faulty.
(6) The valve bank relay is faulty.

21
Possible causes:
(1) Electromagnetic valve short circuit to power supply or ground, or lines open-circuit
(2) Fuse failure
(3) Overheat protection of system
(4) ESP damage.

Diagnostic steps
Step Operation Yes No.
1. Cool the car for 5 minutes and then check whether the -- Perform step
fault is eliminated. 2
2. Is a preliminary check carried out? Perform Carry out
Step 3 “Preliminary
check”
3. Measure the voltage of electromagnetic valve power Perform Perform step
supply pins in the connector, check connector, wiring Step 5 4
harness and ground wire. Is a fault found and
eliminated? See the circuit diagram for pin definition.
4. Carry out cross-validation for ESP. If ESP damage is Perform --
ascertained, replace ESP. Is the fault eliminated? Step 5

5. Accelerate to 15km/h and stop the car, diagnose again -- Diagnosis is

to check whether the fault recurs. finished

9.3 Electromagnetic Valve and Valve Bank Relay Failure

Pump motor failure
DTC：C002004

Conditions for setting malfunction:

(1) The pump motor works overload and its temperature is too high. (Overheating protection)
(2) After the reflux pump motor relay working for 60ms, the reflux pump monitor still fails to detect a
voltage signal.
(3) The reflux pump motor relay is not working, but the reflux pump monitor detects the voltage is out
of range for 2.5s.
(4) The reflux pump motor relay stops working, but the reflux pump monitor detects its voltage does
not decrease.

Possible causes:
(1) System overheat protection
(2) The power supply of the pump motor abnormal
(3) The pump motor relay fault (fuse, external relay)
(4) Pump motor failure
(5) The pump motor is improperly grounded.

Diagnostic steps
Step Operation Yes No.

22
1. Cool the car for 5 minutes and then check whether the -- Perform step
fault is eliminated. 2
2. Is a preliminary check carried out? Perform Carry out
step 3 “Preliminary
check”
3. Measure the voltage of the pump motor power supply Perform Perform step
pins of the connectors, and check connectors, wiring step 5 4
harness and ground wire. Is a fault found and
eliminated? See the circuit diagram for pin definition.
4. Carry out cross-validation for ESP. If ESP damage is Perform --
ascertained, replace ESP. Is the fault eliminated? step 5
5. Accelerate to 15km/h and stops the car, then diagnose -- Diagnosis is
again to verify whether the fault is reproduced? finished

9.4 Wheel Speed Sensor Circuit Failure

DTC: C003204, C003504, C003804, C003B04

Conditions for setting malfunction:

(1) ECU detects the wheel speed sensor signal lines shorted to ground.
(2) Wheel speed sensor line is open circuited.

Possible causes:
(1) Wheel speed sensor line is disconnected, and connector is loose or fractured.
(2) Wheel speed sensor signal wiring and power cord are connected reversely.
(3) Signal wiring is shorted to ground.
(4) The air gap is out of specifications.

Diagnostic steps
Step Operation Yes No.
1. Is a preliminary check carried out? Perform step Carry out
2 “Preliminary
check”
2. Check whether the wheel speed sensor is connected Perform step Perform step
properly and if the sensor circuit in the harness is 4 3
open or short. Is a fault found and eliminated? See
the circuit diagram for pin definition.
3. Carry out cross-validation for ESP. If ESP damage is Perform step --
ascertained, replace ESP. Is the fault eliminated? 4
4. Accelerates to 15km/h and stop the car, and then -- Diagnosis is
diagnose again to verify whether the fault is finished
reproduced.

9.5 Wheel Speed Sensor Signal Failure

DTC: C003108, C003408, C003708, C003A08, C024501

Conditions for setting malfunction:
(1) ECU detects wheel speed sensor signal line short-circuited to power .

23
(2) ECU detects wheel speed sensor power line short-circuited to ground.
(3) Wheel speed sensor signal is abnormal.

Possible causes:
(1) Circuit of wheel speed sensor is broken, loosened or broken.
(2) Wheel speed sensor signal wiring is shorted to power.
(3) Wheel speed sensor power wiring is shorted to ground.
(4) Tooth ring not installed, missing teeth, foreign objects clung to the tooth ring, demagnetization or
eccentric tooth ring.
(5) Excessive air gap between the sensor and the tooth ring.
(6) Wheel speed sensor interfered by external magnetic field. (Wheels or axles not demagnetized)
(7) Wheel speed sensor failure
(8) Wrong tooth number of tooth ring.
(9) The tire size does not conform to specifications.
(10) ECU damage
Diagnostic steps
Step Operation Yes No.
1. Is a preliminary check carried out? Perform step Carry out
2 “Preliminary
check”
2. Check whether the wheel speed sensor is connected Perform step Perform step
properly and if the sensor circuit is open or short. Is a 6 3
fault found and eliminated? See the circuit diagram
for pin definition.
3. Check the air gap between the wheel speed sensor Perform step Perform step
and the tooth ring and check whether there is dirt or 6 4
foreign object in the tooth ring and if tooth is missing.
Check for correct tooth number of tooth ring. Is a fault
found and eliminated?
4. Lift the car with a lifter, turn the wheel, and use an Replace the Perform step
oscilloscope to observe if the wheel speed sensor wheel speed 5
signal output conforms to the specifications. Is a fault sensor
found? Perform step
6
5. Carry out cross-validation for ESP. If ECU damage is Perform step --
ascertained, replace ESP. Is the fault eliminated? 6
6. Accelerate to 15km/h and stop the car, and then -- Diagnosis is
diagnose again to verify whether the fault is finished
reproduced?

9.6 ESP ECU Fault

DTC：C055000

Conditions for setting malfunction

(1) ECU power failure.
(2) ECU damage

24
Possible causes:
(1) ESP harness fault.
(2) Fuse failure
(3) ECU fault
Diagnostic steps
Step Operation Yes No.
1. Is a preliminary check carried out? Perform step Carry out
2 “Preliminary
check”
2. Check the connectors, wiring harness and grounding Perform step Perform step
wiring. Is a fault found and eliminated? 4 3
3. Carry out cross-validation for ESP. If ECU damage is Perform step --
ascertained, replace ESP. Is the fault eliminated? 4
4. Diagnose again to verify whether the fault is -- Diagnosis is
reproduced? finished

9.7 CAN Bus Failure

DTC: C100104, U100004
Conditions for setting malfunction:
Vehicle CAN bus communication, configuration information and wiring fault.
Possible causes:
(1) CAN controller failure.
(2) CAN configuration information not matched
(3) CAN Off
Diagnostic steps
Step Operation Yes No.
1. Is a preliminary check carried out? Perform step Carry out
2 “Preliminary
check”
2. Diagnose hardware and software of CAN bus. For Perform step Perform step
more details, please refer to the vehicle service 4 3
manual. Is a fault found and eliminated?
3. Carry out cross-validation for ESP. If ECU damage is Perform step --
ascertained, replace ESP. Is the fault eliminated? 4
4. Diagnose again to verify whether the fault is -- Diagnosis is
reproduced? finished

9.8 Pressure Sensor Failure

DTC：C004601
Conditions for setting malfunction:
(1) Pressure signal interrupted.
(2) Abnormal pressure (Less than the initialization value)

25
Possible causes:
(1) Pressure sensor failure
(2) ESP module failure.
Diagnostic steps
Step Operation Yes No.
1. Is a preliminary check carried out? Perform step Carry out
2 “Preliminary
check”
2. Carry out cross-validation for ESP (See “Removal Perform step --
and installation” for details). If ECU damage is 3
ascertained, replace ESP. Is the fault eliminated?
3. Diagnose again to verify whether the fault is -- Diagnosis is
reproduced? finished

9.9 Steering Wheel Angle Sensor Failure

DTC: U012604, U012608, C046008, C106600
Conditions for setting malfunction:
(1) Steering wheel angle sensor not calibrated or its calibration failed (e.g. the steering wheel not
aligned, the wheel not aligned, four wheel alignment not done, etc.).
(2) Steering wheel angle sensor signal abnormal or sensor not installed in place.
(3) Steering wheel angle sensor signal interrupted.
(4) CAN communication of steering wheel angle sensor failed
Possible causes:
(1) Sensor not calibrated.
(2) Sensor short circuit or open circuit.
(3) Sensor damaged or not installed in place.
(4) ESP failure
Diagnostic steps
Step Operation Yes No.
1. Is a preliminary check carried out? Perform step Carry out
2 “Preliminary
check”
2. Calibrate the steering wheel angle sensor. Is the fault Perform step Perform step
eliminated? 5 3
3. Check the harness of the steering wheel angle Perform step Perform step
sensor. Is the fault eliminated? 5 4
4. Carry out cross-validation for the steering wheel angle Perform step --
sensor or reinstall the angle sensor (this needs 5
recalibration). Is the fault eliminated?
5. Diagnose again to verify whether the fault is -- Diagnosis is
reproduced? finished

9.10 Yaw Rate Sensor (Integrated Sensor) Failure

For ESP9 systems, yaw-rate sensor is an external sensor. For ESP9i system, yaw-rate sensor is
built-in (i.e., integrated sensor).

26
Yaw rate sensor produces three signals: transverse acceleration, longitudinal acceleration and yaw
rate.
DTC: C006108, C006208, C006308, C019604, C00A800

Conditions for setting malfunction:

(1) The yaw-rate sensor not calibrated.
(2) The yaw-rate sensor signal is abnormal.
(3) The yaw-rate sensor failure

Possible causes:
(1) The sensor is not calibrated or its calibration is not conforming to specification (it needs to be
calibrated on a flat surface).
(2) The installation error of the sensor (i.e. ESP module assembly) is too big.
(3) Sensor damaged
Diagnostic steps
Step Operation Yes No.
1. Is a preliminary check carried out? Perform step Carry out
2 “Preliminary
check”
2. Calibrate the yaw-rate sensor (integrated sensor). Is Perform step Perform step
the fault eliminated? 6 3
3. Check the yaw-rate sensor wiring harness. (skip this Perform step Perform step
step for integrated sensor) Is the fault eliminated? 6 4
4. Reinstall and calibrate the yaw rate sensor / ESP9i Perform step Perform step
module. Is the fault eliminated? 6 5
5. Carry out cross-validation for ESP9i module (Require Perform step --
re-calibration). Is the fault eliminated? 6
6. Diagnose again to verify whether the fault is -- Diagnosis is
reproduced? finished

9.11 ECM Failure

DTC: U010004, U010008

Conditions for setting malfunction:
(1) ECM message timeout.
(2) ECM message error.
Possible causes:
(1) CAN bus failure
(2) ECM software version does not match
(3) ECM is damaged.
Diagnostic steps
Step Operation Yes No.
1. Is a preliminary check carried out? Perform step Carry out
2 “Preliminary
check”

27
2. Diagnose hardware and software of CAN bus. Is a Perform step Perform step
5 3
fault found and eliminated?
3. Diagnose ECM version information. For more details, Perform step Perform step
please refer to the vehicle service manual. Is a fault 5 4
found and eliminated?
4. Carry out cross-validation for ECM. If ECM damage is Perform step --
ascertained, replace ECM. Is the fault eliminated? 5
5. Diagnose again to verify whether the fault is -- Diagnosis is
reproduced? finished

9.12 Gateway failure

DTC: U014004, U014008

Conditions for setting malfunction:

(1) Gateway message timeout.
(2) Gateway message error.

Possible causes:
(1) CAN bus failure
(2) Gateway software version does not match
(3) Gateway damaged.

Gnostic steps
Step Operation Yes No.
1. Is a preliminary check carried out? Perform step Carry out
2 “Preliminary
check”
2. Diagnose hardware and software of CAN bus. For Perform step Perform step
more details, please refer to the vehicle service 5 3
manual. Is a fault found and eliminated?
3. Diagnose Gateway version information. Is a fault Perform step Perform step
found and eliminated? 5 4
4. Carry out cross-validation for Gateway. If Gateway Perform step --
damage is ascertained, replace Gateway. Is the fault 5
eliminated?
5. Diagnose again to verify whether the fault is -- Diagnosis is
reproduced? finished

9.13 EPB Failure

DTC: U100304, U 100308, C040008

Conditions for setting malfunction:

(1) EPB message timeout.
(2) EPB message error.
(3) EPB signal failure.

28
Possible causes:
(1) CAN bus failure
(2) EPB software version does not match.
(3) EPB damaged.

Diagnostic steps
Step Operation Yes No.
1. Is a preliminary check carried out? Perform step Carry out
2 “Preliminary
check”
2. Diagnose hardware and software of CAN bus. For Perform step Perform step
more details, please refer to the vehicle service 5 3
manual. Is a fault found and eliminated?
3. Diagnose EPB version information. For more details, Perform step Perform step
please refer to the vehicle service manual. Is a fault 5 4
found and eliminated?
4. Carry out cross-validation for EPB. If EPB damage is Perform step --
ascertained, replace EPB. Is the fault eliminated? 5
5. Diagnose again to verify whether the fault is -- Diagnosis is
reproduced? finished

9.14 ESP PATA Switch Failure

DTC：C004C04

Conditions for setting malfunction:

(1) Press and hold PATA switch continuously for 10 seconds or more.
(2) Monitored PATA active signal lasting over two seconds during the ignition.

Possible causes:
(1) PATA switch is pressed by foreign object.
(2) PATA switch is damaged.

Diagnostic steps
Step Operation Yes No.
1. Check whether the PATA switch is pressed by or Perform step Perform step
stuck to any object and clean the switch. Is the fault 4 2
eliminated?
2. Check PATA switch harness. Is a fault found and Perform step Perform step
eliminated? 4 3
3. Carry out cross-validation for PATA switch. If PATA Perform step --
switch damage is ascertained, replace PATA switch. 4
Is the fault eliminated?
4. Diagnose again to verify whether the fault is -- Diagnosis is
reproduced? finished

29
9.15 ESP Configuration Information Failure
DTC：C121208

Conditions for setting malfunction:

(1) Configuration information is not written.
(2) Configuration information does not match

Possible causes:
(1) Configuration information is not written or written incorrectly.
Diagnostic steps
Step Operation Yes No.
1. Write configuration information of ESP with diagnostic Perform step --
equipment. Is the fault eliminated? 2
2. Diagnose again to verify whether the fault is -- Diagnosis is
reproduced? finished

9.16 Brake lamp switch (BLS) Fault

DTC：C004008

Conditions for setting malfunction:

(1) BLS signal abnormal
(2) BLS signal interrupted
Possible causes:
(1) BLS line short circuit or open circuit.
(2) BLS installation error.
(3) BLS damaged.

Diagnostic steps
Step Operation Yes No.
1. Is a preliminary check carried out? Perform step Carry out
2 “Preliminary
check”
2. Check the installation, fixture and wiring harness of Perform step Perform step
the BLS. Is the fault eliminated? 4 3
3. Carry out cross-validation for BLS. If BLS damage is Perform step --
ascertained, replace BLS. Is the fault eliminated? 4
4. Diagnose again to verify whether the fault is -- Diagnosis is
reproduced? finished

9.17 Abnormal operation of ESP

DTC：C008208
Conditions for setting malfunction:
(1) ESP receives continuous operation instruction (for more r than 10 seconds).

30
Possible causes:
(1) Wheel speed difference is too big.
(2) Sensor signal incorrect.
(3) Signal of steering wheel angle sensor and yaw rate sensor is abnormal
Diagnostic steps
Step Operation Yes No.
1. Is a preliminary check carried out? Perform step Carry out
2 “Preliminary
check”
2. Check the wheel speed sensor and the tooth ring. Is Perform step Perform step
the fault eliminated? 5 3
3. Check the installation of the steering wheel angle Perform step Perform step
sensor and the yaw rate sensor. Is the fault 5 4
eliminated?
4. Carry out cross-validation for ESP (See “Removal Perform step --
and installation” for details). If ECU damage is 5
ascertained, replace ESP. Is the fault eliminated?
5. Diagnose again to verify whether the fault is -- Diagnosis is
reproduced? finished

9.18 Clutch Signal Abnormal

DTC：C108008
Conditions for setting malfunction:
(1) Clutch signal abnormal
Possible causes:
(1) Clutch switch circuit malfunction.
(2) Clutch switch malfunction.
(3) Driving habits of some customers (who step on the clutch pedal for more than 5 minutes).
Diagnostic steps
Step Operation Yes No.
1. Is a preliminary check carried out? Perform step Carry out
2 “Preliminary
check”
2. Diagnose the clutch switch circuit. For more details, Perform step Perform step
please refer to the vehicle service manual. Is a fault 5 3
found and eliminated?
3. Diagnose the hardware of the clutch switch. For more Perform step Perform step
details, please refer to the vehicle service manual. Is 5 4
a fault (contact damage, return not normal) found and
eliminated?
4. Carry out cross-validation for clutch switch. If clutch Perform step --
switch damage is ascertained, replace clutch switch. 5
Is the fault eliminated?
5. Diagnose again to verify whether the fault is -- Diagnosis is
reproduced? finished
9.19 Reverse Gear Signal Abnormal
DTC：C108C08

31
Conditions for setting malfunction:
(1) Reverse gear signal is "1” when the car moves forward.
(2) Reverse gear signal is "0” when the car moves backward.
Possible causes:
(1) Reverse gear switch failure.
(2) BCM communication failure.
(3) Reverse gear signal wiring fault
Diagnostic steps
Step Operation Yes No.
1. Is a preliminary check carried out? Perform step Carry out
2 “Preliminary
check”
2. Diagnose the reverse gear switch wiring. Is a fault Perform step Perform step
found and eliminated? 4 3
3. Diagnose the BCM and body gateway wiring. For Perform step --
more details, please refer to the vehicle service 4
manual. Is a fault found and eliminated?
4. Diagnose again to verify whether the fault is -- Diagnosis is
reproduced? finished

Note: Refer to ABS service manual for diagnosis and repair.

32
10. Removal and Installation
10.1 Removal Steps of ESP Assembly

1. Turn the ignition switch to OFF position and disconnect battery terminal negative;
2. Remove the harness from the ESP assembly.
3. Depress the brake pedal to maximum extent and fix with the pedal support, in order to prevent the
brake fluid from flowing out when taking out the brake piping from the brake master cylinder.
4. Remove the brake lines and block the threaded hole in the ESP assembly and oil hole on the
brake lines with a plug, to prevent impurities from entering.
5. Remove ESP from the mounting bracket.
10.2 Installation Steps of ESP Assembly

1. Install the ESP assembly to the bracket with a tightening torque of 8 ± 2Nm.
2. Remove the plugs from ESP thread hole and brake lines. Insert the brake lines into ESP assembly
to a tightening torque of 16 ± 2Nm.
3. Add brake fluid to the liquid-storage tank to Max level and exhaust according to the required
method.
4. Write down the configuration information (if any) after replacing the ESP assembly
5. After replacing the ESP assembly, the steering wheel angle sensor and yaw rate sensor
(integrated sensor) must be calibrated.
10.3 Exhaust Description

‧ After replacing brake system components (such as replacement of brake fluid, brake lines,
hydraulic unit) or brake pedal is too soft, air in the brake line must be exhausted.
‧ The replacement hydraulic unit must be ECU ESP hydraulic regulator filled with oil.
‧ The structural integrity of the brake system must he ensured and all high-pressure hydraulic units
must be properly connected while exhausting.
‧ Pull up the parking brake before exhausting.
‧ The brake fluid is corrosive. If it is spilled on your skin, wash with clean water immediately.
10.4 Integrated Sensor Calibration Instructions (ESP9i System)

ESP9i system integrates yaw-rate sensor, so its installation precision is high. When replacing the
system, the installation error must be less than ± 5 °, or it cannot be calibrated.
Integrated sensor calibration
Operator Test bench/Test equipment
Turn the steering wheel to straight ahead position Calibrate the offset of the integrated inertial
The car should be in the straight ahead position sensor
on the test equipment.
Preconditions of sensor offset calibration
• The maximum tilt angle of the test bench must be within the allowable range (meet the requirement
in both alignment directions, please refer to the chart below).
• The test bench must be stationary.
• Turn the steering wheel to the straight ahead position.
• Correct tire pressure.
• Under normal load
• Allow low volume fuel tank
• Vehicle is supported by its own wheels

33
• Only the driver must sit in the car
• No extra interference permitted such as closing the door or engine front hood
• Calibration may be performed on the hub tester, or on the flat ground.

Please note! Maximum allowable tilt angle is ±0.57° in IIS calibration.

Remarks:
At delivery ESP EEPROM already has stored predetermined offset. In the calibration process, ECU
will write the new data measured into EEPROM for use by ESP. ESP cannot ascertain
aforementioned preconditions, so the customer must make sure that these calibration conditions are
met. If the offset is too big, the system will reject calibration and the vehicle must be returned for
maintenance. IIS calibration should be carried out after replacing ESP9i.

Side view of car (IIS calibration)

Front view of car (IIS calibration)

34
11. Service Technical Parameters
11.1 General Technical Parameters
Model BYD G5
Brake lines arrangement X-type
Drive type Front wheel drive
System Bosch ESP 9
Brake fluid model Specified by BYD Mixed use is
prohibited
Tooth number of tooth ring 48.
Internal resistance of wheel speed sensor 3M ~5M
Air gap between the wheel speed sensor and the tooth 0.1~0.9mm
ring
Front wheel
Rear wheel 0.2~0.7mm
205/50R17
Tire model 225/45R18
Spare tire：T135/90 R16 102M

11. 2 Torque (Unit: N · M)

Brake pipe fittings on the ESP ECU 14~18
ESP fixing bolts 12
Fixing bolts of front wheel speed sensor 10
Fixing bolts of rear wheel speed sensor 10

35