Pressure Bleeding

ABS BLEEDING PROCEDURE
Prior to bleeding the brakes, the front and rear displacement cylinder pistons must be returned to the top most position. Using a TECH 1 or T-100 (CAMS), enter the manual control function and "apply" the front and rear motors. Be sure the enable relay is "ON."

If a TECH 1 or T-1OO are not available, bleed the front brakes. Start engine and allow it to run for at least 10 seconds, (with foot off brake) this will cause the ABS to initialize itself. This will return the front and rear displacement cylinders to the top position. The entire brake system should now be rebled.

CAUTION: 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.

(Figure 1) ABS Pressure Bleeding:

Brake Pipe Connections:

PRESSURE BLEEDING
The pressure bleeding equipment MUST be of the diaphragm type and have a rubber diaphragm between the air supply and the brake fluid to prevent air, moisture and other contaminants from entering the hydraulic system. Follow ALL the steps below with pressure bleeding equipment connected and pressurized to complete system bleeding.

1. Clean master cylinder cover and surrounding area.
2. Remove master cylinder cover and inspect fluid level. Add clean brake fluid as required.
3. Connect pressure bleeding equipment with bleeder adapter (J-35589) to master cylinder reservoir.
4. Connect clear plastic bleeder hose to bleeder valve and submerge other end of in clean container partially filled with brake fluid.
5. Adjust pressure bleed equipment to 35 - 70 kPa (5 - 10 psi) and wait for approximately 30 seconds to insure there is no leakage, then readjust pressure to 205 - 240 kPa (30 - 35 psi).
6. With bleeder hose connected to rearward bleeder valve on ABS hydraulic modulator assembly.
7. Slowly open bleeder valve (figure 1) and allow fluid to flow until no air is seen in fluid. Close valve when fluid flows without any air bubbles and tighten to 7 Nm (65 lb in).
8. Relocate bleeder hose on the forward bleeder valve on the ABS hydraulic modulator assembly and repeat step 7.

NOTE: Use a shop cloth to catch escaping brake fluid as a bleeder hose is not used to bleed brake pipe connections.

9. Crack (slightly open) upper (forward) brake pipe tube nut on ABS hydraulic modulator assembly (figure 2) and check for air in escaping fluid.
10. When air flow ceases, immediately tighten tube nut, then torque to 32 Nm (24 lb ft).
11. Repeat steps 9 and 10 for remaining three brake pipe connections, moving from front to rear.
12. Raise vehicle and suitably support.

NOTES:
^ Bleed wheel brakes in sequence shown below:
a. Right rear.
b. Left rear.
c. Right front.
d. Left front.

^ To assist in freeing entrapped air from calipers, tap LIGHTLY on caliper castings with a rubber mallet.

13. Attach bleeder hose to right rear bleeder valve and submerge opposite hose end in clean container partially filled with brake fluid.
Slowly open bleeder valve and allow fluid to flow, then close valve when fluid begins to flow without any air bubbles.
14. Repeat step 13 on left rear wheel brake and then on front wheel brakes.
15. Lower vehicle and remove bleeder equipment.
16. Check fluid level in reservoir and fill to the correct level, if necessary, using clean brake fluid.
17. Install 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 18.

^ 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. 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.