Hydraulic System: Service and Repair
FLUSHING BRAKE HYDRAULIC SYSTEMCAUTION: Use only SUPREME 11 or equivalent DOT 3 brake fluid from a clean, sealed container. Do not use fluid from an open container that may be contaminated with water. Improper or contaminated fluid will result in damage to components or loss of braking, with possible personal injury.
CAUTION: Do not overfill the brake fluid reservoir. Overfilling the brake fluid reservoir may cause the brake fluid to overflow onto the engine exhaust components during brake system service. The brake fluid is flammable and may cause a fire and personal injury if the brake fluid contacts the engine exhaust system components.
PRESSURE FLUSHING
^ Tools Required
- J 29532 Diaphragm Type Brake Bleeder
- J 35589 Compact Brake Bleeder Adapter
IMPORTANT:
^ If evidence of contamination is present in the vehicle's brake fluid, flush the entire brake system following one of the following procedures.
^ Flush the system under the following conditions:
^ If there is any doubt about the condition of the fluid in the system
^ If the fluid that is used contains the slightest trace of mineral oil (from such things as engine oil, transmission fluid, etc.)
^ After flushing the entire brake system, replace all rubber components.
^ Replace the following components:
^ The brake hose assemblies
^ The master cylinder rubber parts
^ The brake caliper and wheel cylinder boots and seals
^ The brake modulator
^ The brake solenoid valves
^ Refer to the appropriate replacement procedures.
^ After replacing all rubber components, re-flush the entire brake system by performing one of the following procedures.
^ After performing the second flushing procedure, perform a complete system bleed.
NOTICE: Pressure Bleeding equipment can be used to perform the flush procedure. The pressure bleeding equipment used for flushing must be of the diaphragm type. It must a have a rubber diaphragm between the air supply and the brake fluid to prevent air, moisture, and other contaminants from entering the hydraulic system.
1. Clean the brake fluid reservoir cover and the surrounding area.
2. Remove the brake fluid reservoir cover.
3. Remove any remaining brake fluid in the reservoir.
4. Refill the brake fluid reservoir with clean DOT 3 brake fluid to the proper level.
5. Install the J 35589 to the brake fluid reservoir.
6. Install the J 35589 to the pressure bleeding equipment.
7. Adjust the pressure bleeding equipment to 35 - 70 kPa (5 - 10 psi) and wait for approximately 30 seconds in order to ensure there is no leakage.
8. Adjust the pressure bleeding equipment to 205 - 240 kPa (30 - 35 psi).
9. After connecting the pressure bleeding equipment and pressurizing the system, perform the following steps:
9.1. Attach a clear plastic hose to the rearward bleeder valve on the brake modulator.
9.2. Place the other end of the hose in a container in order to collect draining brake fluid. Do not submerge the hose end into the fluid.
9.3. Slowly open the bleeder valve. Allow the brake fluid to flow clean or until at least 118 ml. (4 oz.) of fluid accumulates.
9.4. Close the valve.
NOTICE: Refer to Fastener Notice in Service Precautions.
9.5. Repeat the above procedure for the forward bleeder valve until clean brake fluid flows or until at least 118 ml. (4 oz.) of fluid accumulates.
^ The ABS brake modulator bleeder valves to 9 Nm (80 inch lbs.).
10. Complete the following procedure after connecting the pressure bleeding equipment:
10.1. Remove the traction control module bolt to bracket in order to access the bleeder valves.
10.2. Attach a clear plastic hose to the right side bleeder valve on the traction control module.
10.3. Place the other end of the hose in a container in order to collect draining brake fluid. Do not submerge the hose end into the fluid.
10.4. Slowly open the bleeder valve. Allow the brake fluid to flow clean or until at least 118 ml. (4 oz.) of fluid accumulates.
10.5. Close the valve.
10.6. Repeat the above procedure for the left side bleeder valve until clean brake fluid flows or until at least 118 ml. (4 oz.) of fluid accumulates.
^ Tighten the traction control module bleeder valves to 9 Nm (80 inch lbs.).
^ Tighten the traction control module bolt to bracket to 3 Nm (27 inch lbs.).
11. Raise and suitably support the vehicle.
12. The following list indicates the wheel position flush sequence:
^ Right rear
^ Left rear
^ Right front
^ Left front
IMPORTANT: Ensure that the bleeder valves do not leak.
13. Use the following procedure in order to flush the brakes:
13.1. Attach the bleeder hose to the bleeder valve at each wheel.
13.2. Place the other end of the bleeder hose into a container in order to collect the draining brake fluid. Do not submerge the hose end in fluid.
13.3. Slowly open the bleeder valve and allow the fluid to flow.
13.4. Close the valve when clean brake fluid begins to flow or at least 235 ml. (8 oz.) of fluid accumulates.
13.4.1. Tighten the front caliper bleeder valves to 13 Nm (115 inch lbs.).
13.4.2. Tighten the rear caliper bleeder valves to 7 Nm (62 inch lbs.).
13.4.3. Tighten the rear wheel cylinder bleeder valves to 7 Nm (62 inch lbs.).
14. Lower the vehicle.
15. Remove the bleeder adapter.
16. Replace all the rubber components listed under Flushing Procedure.
17. Repeat the flushing procedure one more time.
18. Inspect the brake fluid level in the reservoir. Fill the reservoir to the correct level if necessary.
19. Install the brake fluid reservoir cap.
20. Bleed the entire brake hydraulic system.
MANUAL FLUSHING
IMPORTANT: Use a suitable container and/or shop rags in order to catch fluid and prevent the fluid from contacting any painted surfaces.
1. Clean the brake fluid reservoir cover and the surrounding area.
2. Remove the brake fluid reservoir cover.
3. Remove any remaining brake fluid in the brake fluid reservoir.
4. Refill the brake fluid reservoir with clean DOT 3 brake fluid to the proper level.
5. Install the brake fluid reservoir cover.
6. Use the following procedure in order to flush the brake modulator:
6.1. Attach a clear plastic bleeder hose to the rearward bleeder valve on the brake modulator.
6.2. Place the other end of the hose in a container in order to collect the draining brake fluid. Do not submerge the hose end in fluid.
6.3. Slowly open the rearward bleeder valve one half to one full turn.
6.4. Depress the brake pedal until the fluid begins to flow.
6.5. Close the valve and release the brake pedal. Repeat the above steps until clean brake fluid flows or at least 118 ml. (4 oz.) of fluid accumulates.
NOTICE: Refer to Fastener Notice in Service Precautions.
6.6. Repeat the procedure for the forward bleeder valve until clean brake fluid flows or at least 118 ml. (4 oz.) of fluid accumulates.
^ Tighten the ABS brake modulator bleeder valves to 9 Nm (80 inch lbs.).
7. Perform the following steps in order to flush the traction control module.
7.1. Remove the traction control module bolt to bracket in order to access the bleeder valves.
7.2. Attach a clear plastic bleeder hose to the right side bleeder valve on the traction control module.
7.3. Place the other end of the hose in a container in order to collect the draining brake fluid. Do not submerge the hose end in fluid.
7.4. Slowly open the bleeder valve one half to one full turn.
7.5. Depress the brake pedal until the fluid begins to flow.
7.6. Close the valve and release the brake pedal. Repeat the above steps until clean brake fluid flows or at least 118 ml. (4 oz.) of fluid accumulates.
7.7. Repeat the procedure for the left side bleeder valve until clean brake fluid flows or at least 118 ml. (4 oz.) of fluid accumulates.
7.7.1. Tighten the traction control module bleeder valves to 9 Nm (80 inch lbs.).
7.7.2. Tighten the traction control module bolt to bracket to 3 Nm (27 inch lbs.).
8. Inspect the brake fluid level in the following manner:
8.1. Remove the brake fluid reservoir cover.
8.2. Inspect the brake fluid level in the reservoir. Fill the reservoir to the correct level if necessary.
8.3. Replace the brake fluid reservoir cover.
9. Raise and suitably support the vehicle.
10. The following list indicates the wheel position flush sequence:
^ Right rear
^ Left rear
^ Right front
^ Left front
Use the sequence shown above.
IMPORTANT: Ensure that the bleeder valves do not leak.
11. Use the following procedure in order to flush the brakes:
11.1. Attach the bleeder hose to the bleeder valve at each wheel.
11.2. Place the other end of the bleeder hose into a container in order to collect the draining brake fluid. Do not submerge the hose end in fluid.
11.3. Slowly open the bleeder valve and allow the fluid to flow.
11.4. Close the valve when clean brake fluid begins to flow or at least 235 ml. (8 oz.) of fluid accumulates.
^ Tighten the front caliper bleeder valves to 13 Nm (115 inch lbs.).
^ Tighten the rear caliper bleeder valves to 7 Nm (62 inch lbs.).
^ Tighten the rear wheel cylinder bleeder valves to 7 Nm (62 inch lbs.).
12. Lower the vehicle.
13. Replace all of the following rubber components:
^ The brake hose assemblies
^ The master cylinder rubber parts
^ The brake caliper and wheel cylinder boots and seals
^ The brake modulator
^ The brake solenoid valves
14. Repeat this manual flushing procedure one more time.
15. Inspect the brake fluid level in the reservoir. Fill the reservoir to the correct level if necessary.
16. Replace the brake fluid reservoir cap.
17. Bleed the entire brake hydraulic system.