With ABS
INSPECTIONThe hydraulic lines of this brake system are based on a diagonal split system. When a brake line or hose is disconnected, bleeding operation must be performed at both ends of the line disconnected.
Prior to bleeding brakes, both front and rear displacement cylinder pistons must be returned to the top-most or home position. Motor re-home cannot be performed if current diagnostic trouble codes (DTC) are present. If DTC's are present, vehicle must be repaired and DTC's cleared before performing the motor rehome function. Perform this procedure as follows:
Raise and suitably support front end of vehicle so that the drive wheels are off of the ground.
Start engine, engage transaxle and run vehicle above 3 mph for at least ten seconds. Observe ABS indicator. Ensure indicator goes out after three seconds.
If ABS indicator remains illuminated, a Tech-1 or equivalent must be used to diagnose malfunction.
If ABS indicator goes out and stays off, stop engine and repeat previous three steps using Tech-1 or equivalent , enter manual control function and apply the front and rear motors.
1. Fill master cylinder reservoir. Reservoir should be kept at least half full during bleeding operation.
Fig. 8 ABS Bleeder Screw Location:
2. Remove bleeder screw cap, then attach vinyl tube to bleeder screw "A", Fig. 8, or component to be bled. Insert other end of tube into suitable container.
3. Depress brake pedal several times, then while holding pedal depressed, loosen bleeder screw 1/2 turn.
4. When fluid pressure in cylinder is almost depleted, retighten bleeder screw.
5. Repeat steps 3 and 4, until there are no more air bubbles in hydraulic line.
6. When bubbles stop, depress and hold brake pedal, then tighten bleeder screw to specification.
7. Attach bleeder cap.
8. Repeat steps 1 through 6 for bleeder plug "B", Fig. 8.
Fig. 9 Wheel Bleed Sequence:
9. Bleed brake calipers and wheel cylinders as shown, Fig. 9.
10. Start with wheel cylinder or caliper farthest from master cylinder, then bleed front caliper of same brake line.
11. After completing bleeding operation, apply fluid pressure to hydraulic system and check for leakage.
12. Fill master cylinder reservoir up to specified level.
13. Check brake pedal for sponginess. If pedal is spongy, repeat entire procedure.
WHEEL BLEED SEQUENCE
Refer to Fig. 9 for brake bleeding sequence. Bleed brakes as outlined below.
PRESSURE BLEEDING
1. Remove master cylinder cover, ensure reservoir is properly filled.
2. Connect bleeder adapter tool No. J 35589, or equivalent, to master cylinder reservoir.
3. Connect bleeder adapter to pressure bleeding equipment.
4. Connect a clear plastic bleeder hose to modulator assembly rearward bleeder valve, submerge other end of hose into clean container partially filled with brake fluid.
5. Adjust pressure bleeding equipment to 5-10 psi, then wait for approximately 30 seconds to ensure there is no leakage.
6. Adjust pressure bleed equipment to 30-35 psi.
7. To bleed ABS hydraulic modulator and master cylinder, proceed as follows:
a. Slowly open rearward bleeder valve and allow fluid to flow until no air is seen in fluid, then torque valve to 65 inch lbs.
b. Attach bleeder hose to modulator assembly forward bleeder hose.
c. Slowly open forward bleeder valve and allow fluid to flow until no air is seen in fluid, then torque valve to 65 inch lbs.
8. To bleed brake pipe to modulator assembly connections, proceed as follows:
a. Place a shop cloth between brake pipe connections and the top of the motor pack assembly.
b. Loosen forward most brake pipe nut and check for air escaping in fluid.
c. When air flow ceases, torque brake pipe nut to 24 ft. lbs.
d. Repeat steps b and c for remaining three brake pipe connections, moving from front to rear.
9. To bleed wheel brakes, proceed as follows:
a. Raise and support vehicle.
b. Attach bleeder hose to bleeder valve of right rear wheel, submerge other end of hose into clean container partially filled with brake fluid.
c. Loosen bleeder valve and allow fluid to flow, close valve when fluid begins to flow without any air bubbles.
d. Repeat steps b and c, first for left rear wheel, then the right front caliper, then the left front caliper.
10. Road test vehicle, to verify brake performance.
MANUAL BLEEDING
1. Ensure brake fluid reservoir is properly filled.
2. Attach bleeder hose to modulator assembly rearward bleed valve, submerge other end of hose into clean container partially filled with brake fluid.
3. Pump brake pedal several times, then slowly open bleeder valve 1/2 to 3/4 turns.
4. Depress brake pedal and hold until fluid begins to flow.
5. Close valve and repeat steps 3 and 4 on forward valve. Once fluid is seen to flow from both the forward and rearward valves, modulator valve and master cylinder are filled sufficiently filled with fluid. However, modulator and master cylinder assemblies may not be purged of air. At this point, bleed the wheel brakes.
6. Raise and support vehicle.
7. Attach bleeder hose to bleeder valve of right rear wheel, submerge other end of hose into clean container partially filled with brake fluid.
8. Open bleeder valve and slowly depress brake pedal, close valve and slowly release brake pedal, wait five seconds.
9. Repeat step 8, until brake pedal feels firm and no air bubbles are observed in bleeder hose.
10. Repeat steps 7, 8 and 9, first for left rear wheel, then the right front caliper, then the left front caliper.
11. Lower vehicle and attach bleeder hose to rearward bleeder valve.
12. Depress brake pedal using moderate pressure, then slowly open bleeder valve 1/2 to 3/4 turns and allow fluid to flow.
13. Close valve and release brake pedal, wait five seconds.
14. Repeat steps 12 and 13, until all air is purged from system.
15. Repeat steps 11, 12, 13 and 14, on forward bleeder valve.
16. Road test vehicle, to verify brake performance.