Brake Bleeding: Service and Repair

BRAKE: BRAKE FLUID: BLEEDING

BLEEDING
CAUTION: Never bleed air from the brake hydraulic system without using Techstream. Failure to use Techstream could cause serious injury or an accident.
NOTICE:
- Move the shift lever to the P position and apply the parking brake before bleeding.
- Add brake fluid carefully and check that the reservoir level remains between the MIN and MAX lines while bleeding the brakes.
- Do not stand the fluid can on the reservoir inlet when bleeding the brake actuator. Doing so will cause brake fluid to overflow.
- The actuator pump motor and solenoid can be operated by the driver even if the power switch is off.
- If the pump motor operates while air still remains inside the brake actuator hose, air will enter the actuator, making it more difficult to bleed the brakes. If there is concern about air remaining in the actuator hose, remove the two motor relays (ABS motor relay No. 2) until instructed to reinstall them.
- Although a buzzer may sound due to a decline in the accumulator pressure while bleeding, it is not necessary to stop bleeding.
- DTCs indicating a malfunction in the motor relays (ABS motor relay No. 2) or the pressure sensor are stored after bleeding. Clear the DTCs when instructed during or after bleeding.

Work list

*1 : Be sure to perform the bleeding operation in the order described.
*2 : If air enters the brake actuator hose because the fluid level in the reservoir is low, be sure to bleed the brake actuator hose.
1. ADD BRAKE FLUID TO RESERVOIR

(a) Add brake fluid to the MAX line in the reservoir.
Fluid:
SAE J1703 or FMVSS No. 116 DOT3
CAUTION:
- Add brake fluid carefully and check that the reservoir level remains between the MIN and MAX lines while bleeding the brakes.
- Do not stand the fluid can on the reservoir inlet when bleeding the brake actuator. Doing so will cause brake fluid to overflow.

2. DISABLE BRAKE CONTROL
(a) When using Techstream:
NOTICE:
- Refer to the Techstream operator's manual for further details.
- Bleed the air by following the steps displayed on Techstream.
(1) Move the shift lever to the P position and apply the parking brake.
(2) Connect Techstream to the DLC3 with the power switch off.
(3) Turn the power switch on (IG).
NOTICE: Do not start the engine.
(4) Turn Techstream on and select "Chassis / ABS/VSC/TRC / Utility / ECB (Electronically Controlled Brake system) Utility / ECB (Electronically Controlled Brake system) Invalid".
CAUTION: If the pump motor operates while air remains inside the brake actuator hose, air will enter the actuator, and this will make bleeding the brakes more difficult.

(b) When removing the ABS motor relay:

(1) Remove the 2 ABS motor relays (ABS motor relay No. 2) with the power switch off in order to disable brake control.
CAUTION: If the pump motor operates while air remains inside the brake actuator hose, air will enter the actuator, and this will make bleeding the brakes more difficult.
NOTICE :
- After the brake actuator assembly has been replaced, remove the ABS motor relay before bleeding the brakes.
- Before removing the brake actuator assembly, make sure to perform accumulator pressure zero down. Removal.

3. BLEED BRAKE ACTUATOR HOSE

(a) Connect SST to the reservoir with the brake reservoir pressure adapter.
SST: 09992-00242
SST: 09992-00350
(b) Loosen the bleeder plug of the actuator.
(c) Connect a vinyl tube to the bleeder plug of the actuator.
(d) Use the SST to boost pressure in the reservoir.
Standard:
50 to 80 kPa (0.5 to 0.8 kgf/cm2, 7.3 to 11.6 psi)
(e) Drain approximately 100 cc (3.4 fl.oz.) of fluid.
(f) Tighten the bleeder plug and boost the pressure in the reservoir again (50 to 80 kPa (0.5 to 0.8 kgf/cm2)). Then, loosen the bleeder plug and bleed the brake actuator hose.
NOTICE: Repeat this procedure at least 5 times.

(g) When air is completely bled out from the hose between the reservoir and the actuator, tighten the bleeder plug.
Torque: 8.3 Nm (85 kgf-cm, 74in-lbf)
4. BLEED MASTER CYLINDER
HINT: If the master cylinder has been disassembled or if the reservoir becomes empty, bleed the air from the master cylinder.

(a) Using SST, disconnect the brake stroke simulator line from the master cylinder.
SST: 09023-00101

(b) Using SST, disconnect the brake line from the master cylinder.
SST: 09023-00101

(d) Cover the outer holes with fingers, and release the brake pedal (Procedure B).
(e) Repeat procedure A and B 3 or 4 times.

(f) Use the SST to fully tighten the brake line.
SST: 09023-00101
Without SST - Torque: 15 Nm (155 kgf-cm, 11ft-lbf)
Without SST - Torque: 14 Nm (143 kgf-cm, 10ft-lbf)
NOTICE :
- If brake fluid leaks onto any painted surface of the vehicle, wash or remove it completely.
- Bleed air by following the steps displayed on Techstream.
- Do not bend or damage the brake line.
- Do not allow any foreign matter such as dirt and dust to enter the brake line from the connecting points.
- Use a torque wrench with a fulcrum length of 250 mm (9.84 in.).
- This torque value is effective when SST is parallel to a torque wrench.
HINT: Air can be easily bled from the front brake system if air has been bled from the master cylinder when replacing the brake master cylinder assembly.

(g) Use the SST to fully tighten the brake stroke simulator line.
SST: 09023-00101
Without SST - Torque: 15 Nm (155 kgf-cm, 11ft-lbf)
Without SST - Torque: 14 Nm (143 kgf-cm, 10ft-lbf)
NOTICE :
- If brake fluid leaks onto any painted surface of the vehicle, wash or remove it completely.
- Bleed air by following the steps displayed on Techstream.
- Do not bend or damage the brake line.
- Do not allow any foreign matter such as dirt and dust to enter the brake line from the connecting points.
- Use a torque wrench with a fulcrum length of 250 mm (9.84 in.).
- This torque value is effective when SST is parallel to a torque wrench.
HINT: Air can be easily bled from the front brake system if air has been bled from the master cylinder when replacing the brake master cylinder assembly.

5. BLEED FRONT BRAKE SYSTEM
HINT: Air can be easily bled from the front brake system if air has been bled from the master cylinder when replacing the brake master cylinder assembly.
NOTICE:
- If brake fluid leaks onto any painted surface of the vehicle, wash or remove it completely.
- Bleed air by following the steps displayed on Techstream.

(a) Depress the brake pedal several times and bleed the front brake system from the bleeder plugs on the front brake cylinders RH and LH.
HINT: Repeat the procedure until air is completely bled from the front brake system.

(b) Tighten the bleeder plugs after bleeding.
Torque: 8.3 Nm (85 kgf-cm, 74in-lbf)
6. CANCEL BRAKE CONTROL DISABLE

(a) Install the 2 ABS motor relays (ABS motor relay No. 2). (If they have been removed.)
(b) Cancel brake control prevention following the prompts on the Techstream screen. (If brake control has been prevented using Techstream.)
7. CLEAR DTC FOR BRAKE CONTROL SYSTEM
HINT: Refer the procedures up to "ELECTRONICALLY CONTROLLED BRAKE SYSTEM". Reading and Clearing Diagnostic Trouble Codes

8. BLEED REAR BRAKE SYSTEM
CAUTION: Never bleed air from the brake hydraulic system without using Techstream. Failure to use Techstream could cause serious injury or an accident.
NOTICE: Bleed air by following the steps displayed on Techstream.

(a) Connect Techstream to the DLC3 with the power switch off.
(b) Check that the parking brake is applied and turn the power switch on (IG).
(c) Turn Techstream on and select "Chassis / ABS/VSC/TRC / Utility / ECB (Electronically Controlled Brake system) Utility / ECB (Electronically Controlled Brake system) Invalid".
(d) With the brake pedal depressed, bleed the rear brake system from the bleeder plug on the rear disc brake cylinder LH while the pump motor and solenoid are operating.
CAUTION: Keep the fluid inside the reservoir above the LOW level by replenishing.
HINT:
- Depress and hold the brake pedal.
- After the solenoid operates for approximately 30 seconds, release the brake pedal to stop the solenoid.
- Repeat the procedures until air is completely bled from the rear brake system.
- The brake control warning light comes on and the buzzer sounds while bleeding, but they do not indicate a malfunction.

(e) Tighten the bleeder plug after bleeding.
Torque: 8.3 Nm (85 kgf-cm, 74in-lbf)
(f) Turn Techstream on and select "Chassis / ABS/VSC/TRC / Utility / ECB (Electronically Controlled Brake system) Utility / ECB (Electronically Controlled Brake system) Invalid".
(g) With the brake pedal depressed, bleed the rear brake system from the bleeder plug on the rear disc brake cylinder RH while the pump motor and solenoid are operating.
CAUTION: Keep the fluid inside the reservoir above the LOW level by replenishing.
HINT:
- Depress and hold the brake pedal.
- After the solenoid operates for approximately 30 seconds, release the brake pedal to stop the solenoid.
- Repeat the procedures until air is completely bled from the rear brake system.
- The brake control warning light comes on and the buzzer sounds while bleeding, but they do not indicate a malfunction.

(h) Tighten the bleeder plug after bleeding.
Torque: 8.3 Nm (85 kgf-cm, 74in-lbf)
9. PERFORM ACCUMULATOR PRESSURE ZERO DOWN
CAUTION:
- Never bleed air from the brake hydraulic system without using Techstream. Failure to use Techstream could cause serious injury or an accident.
- Be sure to perform this procedure before replacement, removal, or installation of the actuator.
NOTICE: Perform accumulator zero down by following the steps displayed on Techstream.

(a) Connect Techstream to the DLC3 with the power switch off.
(b) Depressurize the accumulator.
(1) Check that the parking brake is applied and turn the power switch on (IG).
(2) Turn Techstream on and select "Chassis / ABS/VSC/TRC / Utility / ECB (Electronically Controlled Brake system) Utility / Zero Down" on Techstream.
(3) When the buzzer sounds, turn the power switch off.
(c) Circulate the fluid in the accumulator.
(1) Depressurize the accumulator 5 times.
HINT:
- Accumulator pressure is released and accumulated repeatedly, which circulates the fluid inside the accumulator, when repeating accumulator zero down.
- The pump motor rotates and the accumulator is pressurized every time the power switch is turned from off to on (IG).

10. CHECK BRAKE FLUID LEVEL IN RESERVOIR

(a) After performing accumulator zero down (accumulator depressurizing), return the fluid in the accumulator back to the reservoir and then adjust the fluid level in the master cylinder reservoir to the MAX level.
HINT :
- After performing accumulator zero down (accumulator depressurizing), fluid is built up in the accumulator by turning the power switch on (IG) and the fluid level of the reservoir lowers.
- If the fluid level is adjusted without performing accumulator zero down (accumulator depressurizing), fluid is sent from the accumulator to the reservoir. The fluid level may exceed the MAX level, but it is normal.

11. CLEAR DTC FOR BRAKE CONTROL SYSTEM
HINT: Refer the procedures up to "ELECTRONICALLY CONTROLLED BRAKE SYSTEM". Reading and Clearing Diagnostic Trouble Codes

12. PERFORM LINEAR VALVE OFFSET LEARNING
(a) When the brake actuator assembly is replaced, perform linear valve offset learning after bleeding is completed. Initialization