Bleed System

WARNING: Do not use previously used brake fluid. Ensure that only new fluid is used and that it is taken from a clean sealed container. Carefully dispose of unwanted fluid in a sealed container, marked USED BRAKE FLUID.


Equipment: Bleed the system using a bleed tube and a clean bottle containing a small amount of clean liquid.

CAUTION: Clean all bleed screws, filler cap and connections thoroughly using clean brake fluid only. DO NOT USE MINERAL OIL I.E. ENGINE OIL ETC. MAINTAIN CLEANLINESS THROUGHOUT.

NOTE: During bleed procedure the reservoir fluid level must not fall below the MIN level. Regularly check level and keep topped up to MAX level.


1. Switch OFF ignition and depressurize the system. Ensure that ignition remains OFF until instruction 7.

ABS Reservoir:

2. Fill the fluid reservoir with the specified fluid to the MAX level.

NOTE:
- Time consumed in filling the booster may be reduced by fitting a rubber bellows unit to the filler neck, and using hand pressure to pressurize the reservoir. A spare bellows unit from the booster push rod is suitable for this purpose.
- Ensure the bellows unit is perfectly clean to avoid foreign matter entering the system. Raising the rear of the vehicle will assist the fill procedure.

3. Depress brake pedal slowly and progressively five times, using full pedal stroke. Release the pedal for five to ten seconds, during this time air bubbles will rise into the reservoir.
4. Repeat instruction 3 until some resistance is felt. If no resistance is felt, check that the clevis pin is connected to the correct (UPPER) hole in the brake pedal.

Bleeder Fittings:

5. Bleed the four front caliper lower (hydrostatic) bleed screws in the conventional manner. Proceed in the order: outer bleed screw on the driver's side, opposite caliper outer bleed screw, inner bleed screw, inner bled screw driver's side. Depress the brake pedal slowly and progressively. Lock the bleed screw at the bottom of each stroke.

Hydraulic Pump:

6. Bleed the hydraulic pump - open the bleed screw on the pump and allow fluid to flow until it is clear of air bubbles. Do not use the bleed bottle, use a clean absorbant cloth to prevent fluid spillage.
7. Bleed the accumulator - open the bleed screw. Switch ON ignition, run pump for 3-4 secs, switch off and repeat procedure until no further air bubbles enter bleed bottle. Switch OFF ignition. Close the bleed screw.
8. Bleed the two hydraulic booster bleed screws. Open one bleed screw, depress the brake pedal, switch ON ignition, run pump until no further air bubbles enter the bleed bottle. Close booster bleed screw, switch OFF ignition and release pedal. Repeat for other bleed screw.
9. Bleed power circuit at four calipers in turn. Depress pedal, open bleed screw, (upper bleed screw on front calipers). Switch ON ignition, run pump for 3-4 secs, switch off and repeat procedure until no further air bubbles enter bleed bottle. Switch OFF ignition, close caliper bleed screw, release pedal.
10. Bleed master cylinder - switch ignition on. System pressure will increase until pump cuts out. If pump does not cut out after running for 45 secs, check system for leaks.
11. Bleed hydrostatic circuit calipers - open one front lower caliper bleed screw. Actuate brake pedal several times, using only the lower two thirds of pedal travel, until no further air bubbles enter the bleed bottle. Stop actuation if fluid warning light comes on and allow pressure to build up.
12. Close caliper bleed screw before releasing pedal, repeat for remaining three hydrostatic bleed screws.
13. Check/top up reservoir fluid level.
14. Dry all connections, fully pressurize system and check for leaks.
15. If two full brake applications switch on pump, from fully charged, rebleed system.