Pressure Bleeding

NOTE: Pressure bleeding equipment must be of the diaphragm type. It must have a rubber diaphragm between the air supply and the brake fluid to prevent air, moisture and other contaminants from entering the hydraulic system.

1. Clean Fluid reservoir cover and surrounding area.

REMOVE OR DISCONNECT
2. Fluid reservoir cover.
3. Fluid to be at proper level. Refer to SECTION 5A. Add clean brake fluid as required.

INSTALL OR CONNECT
4. Bleeder adapter J 35589 to brake fluid reservoir.
5. Bleeder adapter to pressure bleeding equipment.
6. Pressure bleed equipment to 35-70 kPa (5-10 psi) and wait for approximately 30 seconds to insure there is no leakage.
7. Pressure bleed equipment to 205-240 kPa (30-35 psi).
8. Proceed as follows with; pressure bleeding equipment connected and pressurized:
a. Attach a clear plastic bleeder hose to the rearward bleeder valve on the ABS hydraulic modulator. Submerge opposite hose end in a clean container partially filled with clean brake fluid.
b. Slowly open bleeder valve and allow fluid to flow until no air is seen in fluid.
c. Close valve when fluid flows without any air bubbles.
d. Repeat steps 9B and 9C until no air bubbles are present.
e. Relocate the bleeder hose on the forward ABS hydraulic modulator bleeder valve and repeat steps 9a through 9d. Tighten ABS hydraulic modulator bleeder valves to 9 Nm (80 inch lbs.). Use a shop cloth to catch escaping brake fluid. Take care to prevent fluid from running down motor pack and entering the motor pack base or into the electrical connector. Also do not allow brake fluid to contact any painted surfaces as surface damage will occur. If brake fluid does contact any surface, flush surface with water to lessen damage.
9. Proceed to bleed the master cylinder brake connections as follows with pressure bleeding equipment connected and pressurized:
a. Slowly loosen the forward brake pipe tube nut on the master cylinder and check for air in escaping fluid.
b. When air flow ceases, immediately tighten tube nut. Tighten Master cylinder tube nut to 32 Nm (24 ft. lbs.).
c. Repeat steps 10a and 10b for the rearward master cylinder brake pipe connection.
10. Proceed to bleed the brake combination valve connections as follows with pressure bleeding equipment connected and pressurized:
a. Slowly loosen the forward brake pipe tube nut on the brake combination valve and check for air in escaping fluid.
b. When air flow ceases, immediately tighten tube nut. Tighten Brake combination valve tube nut to 18 Nm (13 ft. lbs.).
c. Repeat steps 11a and 11b for the rearward brake combination valve pipe connection.
11. Proceed to bleed the ABS hydraulic modulator brake connections as follows with pressure bleeding equipment connected and pressurized.
a. Slowly loosen the forward brake pipe tube nut on the ABS hydraulic modulator and check for air in escaping fluid.
b. When air flow ceases, immediately tighten tube nut. Tighten ABS hydraulic modulator tube nut to 32 Nm (24 ft. lbs.).
c. Repeat steps 12a and 12b for the remaining ABS hydraulic modulator brake pipe connections, moving from front to rear.
12. Raise vehicle and suitably support.
13. Proceed as follows to bleed the rear wheel brakes:
a. Attach a clear plastic bleeder hose to the right rear wheel bleeder valve and submerge opposite hose end in a clean container partially filled with clean brake fluid.
b. Slowly open bleeder valve and allow fluid to flow.
c. Close valve when fluid begins to flow without any air bubbles. Tap lightly on the caliper or backing plate to dislodge any trapped air bubbles.
d. Relocate bleeder hose to the left rear wheel bleeder valve and repeat steps 13A through 16C.
14. Remove pressure to the pressure bleeding equipment.
15. Attach a clear plastic bleeder hose to the right front wheel bleeder valve and submerge opposite hose end in a clean container partially filled with clean brake fluid.
16. Turn the ignition to "RUN," engine "OFF."
17. Open the bleeder valve and apply the brake until the red "BRAKE" warning lamp turns "ON." This shuttles the brake pressure differential warning valve.
18. Close bleeder valve.
19. Reapply pressure to pressure bleeding equipment.
20. Turn the ignition "OFF." Do not reapply the brakes after closing the bleeder valve.
21. Lower vehicle.
22. Repeat the entire Step 8
23. Raise vehicle and suitably support.
24. Repeat the entire Step 13.
25. Proceed as follows to bleed the front wheel brakes:
a. Attach a clear plastic bleeder hose to the right front wheel bleeder valve and submerge opposite hose end in a clean container partially filled with clean brake fluid.
b. Slowly open bleeder valve and allow fluid to flow.
c. Close valve when fluid begins to flow without any air bubbles. Tap lightly on the caliper to dislodge any trapped air bubbles.
d. Relocate bleeder hose to the left front wheel bleeder valve and repeat steps 25A through 25C.
26. Lower vehicle.
27. Remove pressure bleeding equipment, including bleeder adapter J 35589.
28. Fluid level in reservoir and fill to proper level if necessary.

INSTALL OR CONNECT
29. Fluid reservoir cap.
30. With ignition to "RUN" 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, recheck the pedal travel. If it's still firm and constant and pedal travel is not excessive, go to Step 31. If pedal feels soft or has excessive travel either initially or after the engine is started, the following procedure may be used. With the Tech 1, "Release" then "Apply" each ABS motor 2 to 3 times and cycle each ABS solenoid 5 to 10 times. This procedure will ensure all trapped air has been removed from the ABS hydraulic modulator bores. Now repeat bleeding procedure starting at Step 1
31. Road test the vehicle. Make several normal (non ABS) stops from a moderate speed to ensure proper brake system function Allow adequate cooling time between stops.