D. Bleed Brakes And Verify Proper System Operation

1. IF THE PRIMARY PISTON ASSEMBLY WAS REPLACED, the brake lines must be bled using either pressure bleeding or manual bleeding as described on pages 338-339 of the Bendix Antilock 9 & 10 Service and Diagnostic Procedures Manual (81-699-96086).

NOTE:
It is not necessary to bleed the foundation brakes of the vehicle if only the pump/motor assembly has been replaced.

2. Turn the ignition to the RUN position to energize the pump/motor and pressurize the hydraulic system. Check for leakage at the HCU and/or pump/motor.

3. With the ignition key in the OFF position, pump the brake pedal a minimum of 40 times. A noticeable change in the pedal feel will occur when the accumulators are discharged.

WARNING:
Brake system is under extreme pressure. The hydraulic control unit (HCU) may be charged with hydraulic pressure up to 2200 psi. Failure to de-pressurize the accumulators could result in personal injury and/or damage to painted surfaces. Wear safety goggles when disconnecting system fluid lines.

4. Check the brake fluid level in the HCU reservoir and adjust as necessary.

5. Reinstall the air cleaner assembly.

6. With the ignition key in the ON position, monitor the DTC display for four minutes.

^ If any DTC's are displayed, they must be diagnosed and repaired in the order that they are listed on page 221 of the Bendix Antilock 9 & 10 Service and Diagnostic Procedures Manual (81-699-96086).

^ If no DTC's are displayed, continue with Step 7.

7. Using the DRB Scan tool, verify that the stop lamp input reads "ON" when the brake pedal is depressed.

8. Using the DRB scan tool, monitor the accumulator voltage. Depress the brake pedal 40 times. The accumulator voltage should exceed 4.0 volts temporarily just before the pump begins to run.

9. With the brake pedal released, make sure that the boost and primary pressure transducers voltages are both between 0.1 volts and 4.0 volts.

10. Road test the vehicle for a minimum of 5 minutes at various speeds while performing several antilock braking and normal braking stops.

11. With the ignition key in the ON position, check for DTC's.

^ If any DTC's are displayed, they must be diagnosed and repaired in the order that they are listed on page 221 of the Bendix Antilock 9 & 10 Service and Diagnostic Procedures Manual (81-699-96086).