Air Bleeding Procedure for ESC Brake (Step 2)

This procedure should be followed to ensure adequate bleeding of air and filling of the ESC unit, brake lines and master cylinder with brake fluid.

Information 

This work is performed by two people.

• Main worker: Bleeds the system by manually opening and closing the bleed screw and detecting air coming out of brake lines.
• Assistant: Brake pedal operation and scanner operation inside the vehicle.

1. Connect the brake fluid filler to the reservoir tank.
   CAUTION:

   • Do not reuse the drained fluid.
   • Always use genuine DOT3/DOT4 brake Fluid.

     Using a non-genuine DOT3/DOT4 brake fluid can cause corrosion and decrease the life of the system.

   • Make sure that no dirt or other foreign matter is allowed to contaminate the brake fluid.
   • Do not spill brake fluid on the vehicle as it may damage the paint. If brake fluid comes in contact with the paint, wash off immediately with water.
   • Before air bleeding, check all the brake lines for leakage.
   • Check the entire braking system and HCU for normality and installation status.
   • Keep the pressurized state of 3 bar until the air bleeding is completed.
   • Never allow the master cylinder to run out of brake fluid when bleeding the braking system.
2. Connect the KDS to the data link connector located underneath the dash panel.
3. Connect a clear plastic tube to the wheel cylinder bleeder plug and insert the other end of the tube into a half filled clear plastic bottle.
4. Connect the KDS to the data link connector located underneath the dash panel.
5. Select the "HCU Air Bleeding Mode"

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6. Run as KDS screen, send ready signal to Main worker and operate OK button.

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7. When HCU is operated forcibly, keep the wheel bleeder screw (A) with opened state.

   [Front] 

   Tightening torque: 

   13.7 - 19.6 N.m (1.4 - 2.0 kgf.m, 10.1 - 14.4 lb.ft)

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   [Rear] 

   Tightening torque: 

   13.7 - 19.6 N.m (1.4 - 2.0 kgf.m, 10.1 - 14.4 lb.ft)

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8. Depress the brake pedal with strong force at regular intervals while HCU is operated forcibly.

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9. Repeat the above procedure until the air bubbles are completely removed.
10. When HCU forced operation is completed, send the "work end" signal.

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11. Close the wheel bleeder screw (A).
12. Work in the order shown in the figure below.
    Fig 1: Brake Bleedinig Sequence

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13. Check the brake pedal stroke.

    Pedal stroke:  135 ± 3 mm (5.3149 ± 0.1181 in.)