Pressure Bleeding

BLEEDING SYSTEM

NOTICE: Prior to bleeding the brakes, the following procedure must be followed to ensure the front and rear displacement cylinder pistons are returned to the top most position.
Start engine and allow it to run for at least 10 seconds (with foot off brake), this will cause the ABS to initialize itself. Make sure the ABS indicator lamp is "OFF" after about 3 seconds. If the lamp remains "ON," a Tech 1 must be used to diagnose the illumination of the indicator lamp.
If lamp goes "OFF" and stays "OFF," repeat this procedure one more time, Using Tech 1 or T-100, enter the "Manual Control" function and "Apply" the front and rear motors. The entire brake system should now be bled following either "Pressure Bleeding" or "Manual Bleeding" outlined below,

NOTICE: Use only DOT 3 brake fluid from a clean, sealed container. Do not use fluid from an open container that may be contaminated with water. Do not use DOT 5 brake fluid.

PRESSURE BLEEDING

Attaching Bleeder Tube:

TOOLS REQUIRED:
^ J 35589 Bleeding Adapter

NOTICE: Pressure bleeding equipment must be of the diaphragm type. It must have a rubber diaphragm between the air supply and the brake fluid to prevent air, moisture and other contaminants from entering the hydraulic system.

CLEAN
^ Fluid reservoir cover and surrounding area.

REMOVE OR DISCONNECT
^ Fluid reservoir cover.

INSPECT
^ Fluid to be at proper level. Add clean brake fluid as required.

INSTALL OR CONNECT
1. Bleeder adapter J 35589 to brake fluid reservoir.
2. Bleeder adapter to pressure bleeding equipment.
3. Clear plastic bleeder hose to rearward bleeder valve.
^ Submerge other end of bleeder hose in clean container partially filled with brake fluid.

ADJUST
^ Pressure bleed equipment to 35-70 kPa (5-10 psi) and wait for approximately 30 seconds to insure there is no leakage.
^ Pressure bleed equipment to 205-240 kPa (30-35psi).

HYDRAULIC MODULATOR/MASTER CYLINDER ASSEMBLY

NOTE:Proceed as follows with pressure bleeding equipment connected and pressurized.
4. With bleeder hose connected to rearward bleeder valve on hydraulic modulator, slowly open bleeder valve and allow fluid to flow until no air is seen in fluid.
5. Close valve when fluid flows without any air bubbles. Reopen and repeat Steps 4 and 5 until no air bubbles exist.

TIGHTEN
^ Bleeder valve to 9 Nm (80 lb. in.).

6. Relocate bleeder hose on the forward bleeder valve on the hydraulic modulator and repeat Steps 4 and 5.

BRAKE PIPE CONNECTIONS

Brake Pipe Connections:

^ Proceed as follows with pressure bleeding equipment connected and pressurized.

IMPORTANT: Use a shop cloth to catch escaping brake fluid. Take care to prevent fluid from running down motor pack and into the bottom or electrical connector. A bleeder hose is not used to bleed brake pipe connections.

7. Crack (slightly open) forward brake pipe tube nut on hydraulic modulator and check for air in escaping fluid.
8. When air flow ceases, immediately tighten tube nut.

TIGHTEN
^ Tube nut to 24 Nm (18 lb. ft.).

9. Repeat Steps 4 and 5 for remaining three brake pipe connections, moving from front to rear.

WHEEL BRAKES
10. Raise vehicle and suitably support.

IMPORTANT:
^ Bleed sequence:
- Right rear.
- Left rear.
- Right front.
- Left front.

11. Bleed wheel brakes in sequence.
^ Attach bleeder hose to bleeder valve and submerge opposite hose end in clean container partially filled with brake fluid.
^ Slowly open bleeder valve and allow fluid to flow.
^ Close valve when fluid begins to flow without any air bubbles. Tap lightly with a rubber mallet to dislodge any trapped air bubbles.
12. Repeat above sequence on left rear wheel brake.
13. Repeat above sequence on front wheel brakes.
14. Lower vehicle.
15. Remove bleeder adapter J 35589.
16. Check fluid level in reservoir and fill to the correct level using clean brake fluid, if necessary.
17. Install fluid reservoir cover and diaphragm assembly.

INSPECT
^ With ignition "ON," apply brake pedal with moderate force and hold. Note pedal travel and feel.
^ If pedal feels firm and constant and pedal travel is not excessive, start the engine. With the engine running, re-check the pedal travel. If it's still firm and constant and pedal travel is not excessive, go to Step 7.
^ If pedal feels soft or has excessive travel either initially or after engine start. Use the Tech 1, "Release" then "Apply" the motors 2 to 3 times and cycle the solenoids 5 to 10 times. Be sure to "Apply" the front and rear motors to ensure the pistons are in the upmost position. Now repeat bleeding procedure.

18. Road test the vehicle.
^ Make several normal (non ABS) stops from a moderate speed to ensure proper brake system function.