Component Tests and General Diagnostics
Operation and Leakage Check
Check all of the following items:
Brake System Bleeding
CAUTION:
- Do not reuse the drained fluid.
- Always use genuine DOT3/DOT4 brake Fluid.
Using a non-genuine DOT3/DOT4 brake fluid can cause corrosion and decrease the life of the system.
- Make sure no dirt or other foreign matter is allowed to contaminate the brake fluid.
- Do not spill brake fluid on the vehicle, it may damage the paint; if brake fluid does contact the paint, wash it off immediately with water.
- The reservoir on the master cylinder must be at the MAX (upper) level mark at the start of bleeding procedure and checked after bleeding each brake caliper. Add fluid as required.
1. Make sure the brake fluid in the reservoir is at the MAX(upper) level line.
2. Have someone slowly pump the brake pedal several times, and then apply pressure.
3. Loosen the right-rear brake bleed screw (A) to allow air to escape from the system. Then tighten the bleed screw securely.
Front Disc Brake
Rear Disc Brake [Without EPB]
Rear Disc Brake [With EPB]
4. Repeat the procedure for wheel in the sequence shown below until air bubbles no longer appear in the fluid.
5. Refill the master cylinder reservoir to MAX(upper) level line.
Follow this procedure when performing initial air bleeding after installing a new EPB caliper.
1. Loosely tighten the caliper on the vehicle, and then perform air bleeding a number of times in the same way as performed on a general caliper. (For both LH/RH)
2. Remove the caliper from the vehicle, and then press the brake pedal to get the piston to protrude(A). (Make the two pads and the piston come in contact. You may insert a block that has a disc thickness of about 5 mm between the pads.)
3. Move the caliper position so that the bleed screw (A) is facedown, and then press the brake pedal to let out the brake oil. (2 - 3 times)
4. Move the caliper so that the bleed screw (A) is facing upward, as shown in the diagram.
5. Open the bleed screw from this position, and press the brake pedal to let out more oil and air. (More than 5 times)
6. Push in the piston and mount the caliper on the vehicle. Then repeat steps 2 - 5 for the caliper on the opposite side. Then install both calipers on to the vehicle.
7. Pump hard on the brake pedal a few times, and then loosen the bleed screw to let out oil with high pressure. Then quickly tighten the bleed screw. (About 3 times) Complete the procedure. (For both LH/RH)
Bleeding of ESC Brake System
This procedure should be followed to ensure adequate bleeding of air and filling of the ESC unit, brake lines and master cylinder with brake fluid.
1. Remove the reservoir cap and fill the brake reservoir with brake fluid.
CAUTION:
If there is any brake fluid on any painted surface, wash it off immediately.
NOTE:
When pressure bleeding, do not depress the brake pedal.
Recommended fluid. DOT3 or DOT4
2. Connect a clear plastic tube to the wheel cylinder bleeder plug and insert the other end of the tube into a half filled clear plastic bottle.
3. Connect the GDS to the data link connector located underneath the dash panel.
4. Select and operate according to the instructions on the GDS screen.
CAUTION:
You must obey the maximum operating time of the ESC motor with the GDS to prevent the motor pump from burning.
(1) Select vehicle name.
(2) Select Anti-Lock Brake system.
(3) Select HCU air bleeding mode.
(4) Press "OK" to operate motor pump and solenoid valve.
(5) Wait 60 sec. before operating the air bleeding.
(If not, you may damage the motor.)
(6) Perform the air bleeding.
5. Pump the brake pedal several times, and then loosen the bleeder screw until fluid starts to run out without bubbles. Then close the bleeder screw(A).
Front Disc Brake
Rear Disc Brake [Without EPB]
Rear Disc Brake [With EPB]
6. Repeat step 5 until there are no more bubbles in the fluid for each wheel.
7. Tighten the bleeder screw.
Bleed screw tightening torque:
7 - 13 N.m (0.7 - 1.3 kgf.m, 5.4 - 9.5 lb-ft)