Manual Bleeding

NOTICE:
- If a Powermaster III Unit has been replaced, or if air has entered (or is suspected in) the brakelines, the entire brake system (Powermaster III, lines, and calipers) must be bled at each wheel brake.
- If only a hydraulic part of the Powermaster III Unit has been replaced (bleeder valve, relief valve, tube and nut assembly, accumulator, reservoir, solenoid, or pressure switch), and air has not entered the brake lines, it may only be necessary to bleed the Powermaster III Unit by performing an "ABS Solenoid Bleed and Checkout Test" using 94-00101-A or by bleeding the booster section of the Powermaster III Unit at the bleeder valves.
- Performing an "ABS Solenoid Bleed and Checkout Test" or bleeding the Powermaster III Unit at its bleeder valves will not remove air from the brake lines.

MANUAL BLEEDING PROCEDURES

1. Make sure vehicle ignition is off.
2. Depressurize Powermaster III Unit.
3. Clean and remove reservoir cover and diaphragm assembly.
4. Fill reservoir with brake fluid to the correct level and install reservoir cover.
5. Raise vehicle and suitably support it.

NOTICE:
- If the Powermaster III Unit being bled is a replacement part or there is difficulty when trying to bleed the front master cylinder sections, make sure all air is removed from the master cylinder body by opening the brake pipe tube nuts on the Powermaster III Unit (front two only) approximately 2 turns or until fluid begins to bleed.

6. Bleed right front wheel brake.
- Attach bleeder hose to bleeder valve and submerge opposite end in a clean container partially filled with brake fluid.
- Slowly depress brake pedal.
- Open bleeder valve.
- To assist in freeing trapped air, tap "lightly" on caliper castings with a rubber mallet.
- Close bleeder valve.
- Release brake pedal.
- Check fluid level and add new brake fluid as necessary.
7. Repeat step 6 until brake pedal feels firm at half travel and no air bubbles are observed in the bleeder hose.
8. Repeat steps 6 and 7 on the left front wheel brake.

NOTICE:
- Turn the ignition off if pump motor runs for more than 60 seconds, refer to "Pump Runs Continuously".

9. Turn ignition to the "Run" position without starting the vehicle. Allow the pump motor to run, to pressurize the accumulator.
10. Bleed right rear wheel brake.
- Attach bleeder hose to bleeder valve and submerge opposite end in a clean container partially filled with brake fluid.
- Open bleeder valve.
- With ignition on, slowly depress brake pedal part way, until brake fluid begins to flow from bleeder hose. Allow brake fluid to flow for 15 seconds.
- To assist in freeing trapped air, tap "lightly" on caliper castings with a rubber mallet.

NOTICE:
- Do not fully depress brake Pedal.
- Close bleeder valve and release brake pedal.
- Repeat preceding two substeps until no air bubbles are seen in the bleeder hose.
- Check brake fluid level and add new brake fluid as necessary.
- Fill the rear chamber to approximately 25 mm (1 in.) below full mark at this intermediate stage with system charged.

Important
- Final fluid level must be checked after depressurizing unit as described in step 13.
- Repeat steps 9 and 10 on the left rear wheel brake.
- Lower vehicle

11. Bleed Powermaster III Isolation Valves.
- Attach bleeder hose to bleeder valve on inboard side of Powermaster III Unit and submerge opposite end in a clear container partially filled with brake fluid.
- With ignition still on, apply light force to the brake pedal.
- With the brake pedal applied, slowly open bleeder valve and allow brake fluid to flow until no air is seen in the brake fluid.
- Close bleeder valve when brake fluid begins to flow without air bubbles.
- Repeat procedure on outboard side bleeder valve.
12. Bleed accumulator
- Turn the ignition off and depressurize the Powermaster III Unit, refer to "Depressurizing Powermaster III Unit". Wait two minutes for air to clear from the brake fluid in the reservoir.

NOTICE:
- Never check brake fluid level without fully depressurizing the Powermaster III Unit or overfilling will result.

13. Remove reservoir cover and check brake fluid level in both reservoir sections. Using clean brake fluid from a sealed container, fill the reservoirs to the proper level if necessary.
14. Install reservoir cover and snap all four cover tabs in place on reservoir.
15. Before turning the key to run, manually apply brake pedal with a jabbing (sharp rapid apply) using full force three times.
16. Turn the ignition to "Run" and allow the pump motor to run.

NOTICE:
- Turn the ignition off if the pump motor runs for more than 60 seconds, refer to "Pump Runs Continuously".

17. Bleed booster section of Powermaster III Unit.
- Connect 094-00101. Turn ignition to "Run", without starting the engine, allow the pump to charge the accumulator. When the pump has stopped, perform the "Solenoid bleed and checkout" test.
- If 094-00101 is not available, depress the brake pedal with moderate pressure and turn ignition to "Run" without starting the engine for 3 seconds. Repeat this "Off/Run" procedure 10 times to cycle the solenoids.


Inspect

- Apply brake pedal and note brake pedal feel and travel.
- If brake pedal feels firm and smooth without excessive travel, system is properly bled. Proceed to step 18.
- If brake pedal feel is soft or spongy or pedal travel is excessive, refer to "Excessive Pedal Travel".
- If a "bump" is noted upon initial pedal apply, or pedal apply does not feel smooth and uniform, refer to "Non-Uniform Pedal Apply".
18. Road test vehicle and note pedal travel and feel. If any symptoms described above in "Inspect" appear, refer to the appropriate section.