Manual Bleeding
CAUTION:^ Use only DOT 3 brake fluid from a clean, sealed container. Do not use any fluid from a container which is wet with water. Do not use DOT 5 silicone fluid.
^ Prior to bleeding the rear brakes, the rear displacement cylinder pistons must be returned to the top most position or HOME. To return the pistons to home (top most position), use the PDT, or equivalent to perform SPECIAL TEST, RUN ABS MOTORS, PISTON UP-HOME. This test will run the piston to the top of their travel.
1. Clean brake fluid reservoir cap and area around cap. Remove cap.
2. Fill the master cylinder reservoir with clean brake fluid and keep reservoir at least one half full during the bleed operation.
3. Install fluid reservoir cap.
4. Prime the brake master cylinder and modulator assembly:
a. Attach a transparent tube over the rear modulator assembly bleeder valve and allow the tube to hang submerged in a clean container partially filled with brake fluid.
b. Slowly open bleeder valve 1/2 to 3/4 turn.
c. Depress brake pedal slowly and hold until fluid begins to flow.
d. Close valve and slowly release brake pedal.
^ Torque to 7 Nm (62 inch lbs.)
e. Repeat steps a through d for the front modulator assembly bleeder valve.
NOTE: Master cylinder and hydraulic modulator assembly is sufficiently full of fluid. However, it may not be completely purged of air. At this point move to the wheel brakes and bleed them. This insures that the lowest points in the system are completely free of air and then the master cylinder and hydraulic modulator assembly can be purged of any remaining air.
5. Remove the brake fluid reservoir cap and fill the master cylinder reservoir with clean brake fluid if necessary.
6. Install the fluid reservoir cap.
7. Bleed the calipers in the following order:
1st - Right rear, 2nd - Left rear, 3rd - Right front, 4th - Left front
a. Attach a transparent tube over the caliper assembly bleeder valve and allow the tube to hang submerged in a clean container partially filled with brake fluid.
b. Open bleeder valve 1/2 to 3/4 turn.
NOTE: If brake fluid does not come out of the bleeder valve or hose when performing this procedure to a rear caliper, it may mean that the rear displacement pistons are not at the home or top most position.
c. Slowly depress brake pedal. Watch for air bubbles as the brake fluid leaves the bleeder hose.
d. Close bleeder valve.
^ Torque to 11 Nm (97 inch lbs.) - calipers
e. Release brake pedal.
f. Wait five seconds.
g. Repeat steps b through f including five second wait until brake pedal feels firm at half travel and no air is present in brake line.
NOTE: To assist in freeing entrapped air, tap lightly on caliper casting with a rubber mallet.
8. Repeat step 7 for each wheel in the order specified above.
9. Remove the brake fluid reservoir cap and fill the master cylinder reservoir with clean brake fluid if necessary.
10. Install fluid reservoir cap.
11. Bleed the brake master cylinder and modulator assembly:
a. Attach a transparent tube over the rear modulator assembly bleeder valve and allow the tube to hang submerged in a clean container partially filled with brake fluid.
b. Depress brake pedal with moderate force.
c. Slowly open bleeder valve 1/2 to 3/4 turn and allow fluid to flow.
d. Close valve and release brake pedal.
^ Torque to 7 Nm (62 inch lbs.)
e. Wait five seconds.
f. Repeat steps b through e until all air is purged from the system.
g. Repeat steps a through f for the front modulator assembly bleeder valve until all air is purged from the system.
12. Remove the brake fluid reservoir cap and fill the master cylinder reservoir with clean brake fluid if necessary.
13. Install fluid reservoir cap.
14. Check the brake pedal for firm constant feel and travel both with the engine off (ignition on) and with the engine running.
If pedal feel is firm and constant and travel is not excessive, go to step 15. If pedal feel is not firm and constant or travel is excessive:
a. Use PDT, or equivalent to RUN ABS MOTORS, PISTONS UP-HOME and PISTONS DOWN-REL two times.
b. Using scan tool, home pistons.
c. Start engine and let it run for two seconds after the ABS light goes out.
d. Turn Off engine.
e. Repeat steps c and d nine more times.
f. Re-bleed the entire brake system.
15. Check system for leaks with engine running and brakes applied.
16. Road test the vehicle:
a. Make several normal (non-ABS) stops from a moderate speed.
b. Make one to two ABS stops from a higher speed of approximately 80 km/h (50 mph).
17. After road testing the vehicle, it is recommended that the system be bled again following the steps 1 through 13 and then inspected again. If after inspection the pedal feels firm and constant and pedal travel is not excessive, system is properly bled.