Hydraulic Brake System Bleeding (Manual Bleeding)

^ Tools Required
- J 28434 Wheel Cylinder Bleeder Wrench

Notice: Brake fluid will damage electrical connections and painted surfaces. Use shop cloths, suitable containers, and fender covers to prevent brake fluid from contacting these areas. Always re-seal and wipe off brake fluid containers to prevent spills.

1. Apply the brakes several times with the ignition OFF in order to relieve the brake vacuum reserve.
2. Fill the master cylinder reservoir.
3. Maintain the fluid level during bleeding.
4. If the master cylinder has air in the bore, bleed the master cylinder using the following procedure:
4.1. Disconnect the forward brake pipe connector at the master cylinder.
4.2. Allow the brake fluid to flow from the connector port.
4.3. Connect the brake pipe connector. Do not tighten the brake pipe connector.
4.4. Slowly apply the brake pedal and allow the air to bleed from the loose connector.
4.5. Tighten the connector before releasing the brake pedal.
4.6. Wait 15 seconds.
4.7. Repeat this sequence, including the 15-second wait, until all air is purged from the master cylinder bore.
4.8. Repeat this procedure for the rear brake pipe after you purge all the air from the forward pipe connection.
5. If the Brake Pressure Modulator Valve (BPMV) of the 4WAL system is replaced or if you suspect that air is trapped inside, bleed the BPMV next.
6. Bleed each wheel cylinder in the following sequence:
6.1. Right rear wheel cylinder.
6.2. Left rear wheel cylinder.
6.3. Right front wheel caliper.
6.4. Left front wheel caliper.
7. Attach a hose on the wheel cylinder or caliper bleeder valve.
8. Loosen the bleeder valve 1/2 to 1 turn.
9. Immerse the opposite end of the hose into a container partially filled with clean brake fluid.
10. Slowly apply the brake pedal one time and hold.
11. Tighten the bleeder valve and slowly release the brake pedal.
12. Wait 15 seconds. Check the master cylinder fluid level.
13. Repeat this sequence, including the 15-second wait, until one pint of fluid has been bled and no air is seen in the fluid.

NOTICE: Always use the correct fastener in the proper location. When you replace a fastener, use ONLY the exact part number for that application. The manufacturer will call out those fasteners that require a replacement after removal. The manufacturer will also call out the fasteners that require thread lockers or thread sealant. UNLESS OTHERWISE SPECIFIED, do not use supplemental coatings (paints, greases, or other corrosion inhibitors) on threaded fasteners or fastener joint interfaces. Generally, such coatings adversely affect the fastener torque and joint clamping force, and may damage the fastener. When you install fasteners, use the correct tightening sequence and specifications. Following these instructions can help you avoid damage to parts and systems.

14. Tighten the bleeder valve.
^ Tighten the bleeder valve to 7 Nm (62 inch lbs.).

15. Repeat steps seven through fourteen at each wheel until the brake system is bled.
16. Use a Scan Tool to perform four 4WAL function tests.
17. Re-bleed each wheel circuit.
18. Fill the master cylinder to the proper level. Refer Master Cylinder Reservoir Filling.
19. Check the brake pedal for sponginess, and check the brake warning lamp for an indication of unbalanced pressure. Repeat the bleeding procedure in order to correct either of these conditions.