Filling and Manual Bleeding Procedure

NOTE:
^ The reservoir must be properly filled to insure correct operating conditions. However, brake fluid addition is not usually necessary unless there is a leak, indicated by the BRAKE warning indicator, or the system is being serviced.
^ Use only Delco Supreme 11 Brake Fluid or equivalent DOT 3 brake fluid from a clean, sealed container.
^ Thoroughly clean master cylinder reservoir cover before removal to avoid getting dirt in reservoir.
1. Fill master cylinder reservoir to proper level with brake fluid and keep at least one-half full of fluid during bleeding operation.
^ Have an assistant press brake pedal during bleeding operation.

^ IMPORTANT: Master cylinder reservoir cap must be installed before pressing on brake pedal during bleeding operation. This prevents the reservoir from spraying brake fluid.

^ If master cylinder is known or suspected to have air in the bore, continue to step 2.; otherwise go to step 9.
2. Loosen forward (secondary) brake pipe connection at master cylinder.
3. Allow brake fluid to flow from connector port. Maintain reservoir fluid level.
4. Tighten forward brake pipe connection at master cylinder.
5. Depress brake pedal slowly one time and hold. Loosen forward brake pipe connection at master cylinder to purge air from bore. Tighten connection and then release brake pedal slowly. Wait 15 seconds. Repeat sequence, including 15 second wait, until all air is removed from bore.
6. Tighten forward brake pipe connection to 15 Nm (11 lb. ft.).
7. After all air has been removed at forward connection, repeat steps 2. through 6. to bleed master cylinder at rear primary connection.
8. If it is known that calipers and wheel cylinders do not contain any air, then it is not necessary to bleed them; otherwise, continue to step 9.
9. If all the wheel circuits must be bled, use the following sequence: RH rear, LH rear, RH front, LH front.
10. Raise vehicle and suitable support.
11. Remove bleeder valve cap and place proper size box-end wrench, J 28434, or J 21472 over caliper/cylinder bleeder valve. Attach a transparent tube to bleeder valve and allow tube to hang submerged in a transparent container, partially filled with clean brake fluid.
12. Depress brake pedal slowly one time and hold. Loosen bleeder valve to purge air from caliper/cylinder. Tighten bleeder valve and slowly release pedal. Wait 15 seconds. Repeat sequence, including 15 second wait until all air is removed. It may be necessary to repeat sequence 10 or more times to remove all air. Rapid pedal pumping pushes master cylinder secondary piston down the bore in a manner that makes it difficult to bleed system.
13. Tighten wheel cylinder bleeder valves to 7 Nm (62 lbs. in).
^ Tighten caliper bleeder valve to 13 Nm (10 lbs. ft.).
14. Install bleeder valve caps.
15. Lower vehicle.
16. Fill master cylinder to proper level.
17. Check brake pedal for "sponginess."
^ Repeat entire bleeding procedure to correct "sponginess."
18. When manual bleed is completed, pressure bleed the system using Tech 1 (perform an "Auto Bleed" sequence). Then repeat steps 11. through 14.