Pressure Bleeding

^ Tools Required
- J 35589 Bleeding Adapter

Notice:
^ Use only DOT 3 brake fluid from a clean, sealed container. Do not use any fluid from a container which is wet with water. Do not use DOT 5 silicone brake fluid. Improper brake fluid, mineral oil or water in the fluid may cause the brake fluid to boil or the rubber components to deteriorate. Keep all fluid containers capped to prevent contamination.
^ 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 the fluid reservoir cover and the surrounding area.
2. Remove the fluid reservoir cover.
3. Inspect the brake fluid reservoir level. Add clean brake fluid as required.
4. Install the J 35589 to the brake fluid reservoir.
5. Install the J 35589 to the pressure bleeding equipment.
6. Adjust the pressure bleed equipment to 35 - 70 kPa (5 - 10 psi). Wait approximately 30 seconds in order to ensure that there is no leakage.
7. Adjust the pressure bleed equipment to 205 - 240 kPa (30 - 35 psi).
8. Complete the following procedures with the pressure bleeding equipment connected and pressurized:
8.1. Attach a clear plastic bleeder hose to the rearward bleeder valve on the ABS hydraulic modulator.

Submerge the opposite hose end in a clean container partially filled with clean brake fluid.

8.2. Slowly open the bleeder valve. Allow the fluid to flow until no air is seen in the fluid.
8.3. Close the valve when the fluid flows without any air bubbles.

Important:
^ Use a shop cloth in order to catch escaping brake fluid.
^ Prevent the fluid from running down the motor pack base or into the electrical connector.
^ Do not allow brake fluid to contact any painted surfaces as surface damage will occur.
^ If brake fluid does contact any surface, flush the surface with water in order to lessen the damage.

8.4. Repeat the previous three steps until no air bubbles are present.
8.5. Relocate the bleeder hose on the forward ABS hydraulic modulator bleeder valve.

Submerge the opposite hose end in a clean container partially filled with clean brake fluid.

8.6. Slowly open the bleeder valve. Allow the fluid to flow until no air is seen in the fluid.
8.7. Close the valve when the fluid flows without any air bubbles.

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.

8.8. Repeat the previous two steps until no air bubbles are present.

Tighten the ABS hydraulic modulator bleeder valves to 9 Nm (80 inch lbs.).

9. Bleed the master cylinder brake connections with the pressure bleeding equipment connected and pressurized. Use the following procedure:
9.1. Slowly loosen the forward brake pipe tube nut on the master cylinder. Inspect for air in the escaping fluid.
9.2. When the air flow ceases, immediately tighten the tube nut.

Tighten the master cylinder tube nut to 32 Nm (24 ft. lbs.).

9.3. Repeat the previous two steps for the rearward master cylinder brake pipe connection.
10. Bleed the brake combination valve with the pressure bleeding equipment connected and pressurized. Use the following procedure:
10.1. Slowly loosen the forward brake pipe tube nut on the brake combination valve. Inspect for air in the escaping fluid.
10.2. When the air flow ceases, immediately tighten the tube nut.

Tighten the brake combination valve tube nut to 18 Nm (13 ft. lbs.).

10.3. Repeat the previous two steps for the rearward brake combination valve pipe connection.
11. Bleed the ABS hydraulic modulator brake connections with the pressure bleeding equipment connected and pressurized. Use the following procedure:
11.1. Slowly loosen the forward brake pipe tube nut on the ABS hydraulic modulator. Inspect for air in the escaping fluid.
11.2. When the air flow ceases, immediately tighten the tube nut.

Tighten the ABS hydraulic modulator tube nut to modulator to 32 Nm (24 ft. lbs.).

11.3. Repeat the previous two steps for the remaining ABS hydraulic modulator brake pipe connections. Move from the front to the rear.
12. Raise the vehicle. Support the vehicle.
13. Bleed the rear wheel brakes. Use the following procedure:
13.1. Attach a clear plastic bleeder hose to the right rear wheel bleeder valve.

Submerge the opposite hose end in a clean container partially filled with clean brake fluid.

13.2. Slowly open the bleeder valve. Allow the fluid to flow.
13.3. Close the valve when the fluid begins to flow without any air bubbles. Tap lightly on the caliper or backing plate in order to dislodge any trapped air bubbles.
13.4. Relocate the bleeder hose to the left rear wheel bleeder valve.

Submerge the opposite hose end in a clean container partially filled with clean brake fluid.

Then, repeat the previous two steps.

14. Remove the pressure bleeding equipment.
15. Attach a clear plastic bleeder hose to the right front wheel bleeder valve.

Submerge the opposite hose end in a clean container partially filled with clean brake fluid.

16. Turn the ignition to RUN. Leave the engine OFF.
17. Open the bleeder valve. Apply the brake until the red BRAKE warning lamp turns ON. This action shuttles the brake pressure differential warning valve.

Important: Do not reapply the brakes after closing the bleeder valve.

18. Close the bleeder valve.
19. Reapply pressure to the pressure bleeding equipment.
20. Turn the ignition OFF.
21. Lower the vehicle.
22. Repeat the entire pressure bleeding procedure for the ABS hydraulic modulator.
23. Raise the vehicle. Support the vehicle.
24. Repeat the entire pressure bleeding procedure for the rear wheel brakes.
25. Bleed the front wheel brakes. Use the following procedure:
25.1. Attach a clear plastic bleeder hose to the right front wheel bleeder valve.

Submerge the opposite hose end in a clean container partially filled with clean brake fluid.

25.2. Slowly open the bleeder valve. Allow the fluid to flow.
25.3. Close the valve when the fluid begins to flow without any air bubbles. Tap lightly on the caliper in order to dislodge any trapped air bubbles.
25.4. Relocate the bleeder hose to the left front wheel bleeder valve.

Submerge the opposite hose end in a clean container partially filled with clean brake fluid.

Then, repeat the previous two steps.

26. Lower the vehicle.
27. Remove the pressure bleeding equipment, including the J 35589.
28. Inspect the brake fluid level in the reservoir. Fill the reservoir to the proper level if necessary.
29. Reinstall the brake fluid reservoir cap.
30. Turn the ignition to the RUN position. Apply the brake pedal with moderate force and hold. Note the pedal travel and feel.
30.1. If the pedal feels firm and constant and pedal travel is not excessive, start the engine.
30.2. With the engine running, recheck the pedal travel.
30.3. If the pedal is still firm and constant and pedal travel is not excessive, road test the vehicle.

Make several normal (non-ABS) stops from a moderate speed in order to ensure proper brake system function. Allow adequate cooling time between stops.

31. If the pedal feels soft or has excessive travel either initially or after the engine is started, repeat previous steps.
32. Road test the vehicle. Make several normal (non-ABS) stops from a moderate speed in order to ensure proper brake system function. Allow adequate cooling time between stops.