2002 ISUZU AXIOM air bleeding

POWER±ASSISTED STEERING SYSTEM2A±1
AXIOM
STEERING
POWER-ASSISTED STEERING SYSTEM
CONTENTS
Service Precaution 2A±2. . . . . . . . . . . . . . . . . . . . . .
Diagnosis 2A±2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Description 2A±8. . . . . . . . . . . . . . . . . . . . .
Power Steering System Test 2A±10. . . . . . . . . . . . . .
Maintenance 2A±11. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fluid Level 2A±11. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bleeding The Power Steering System 2A±11. . . . . .
Bleeding Procedure 2A±11. . . . . . . . . . . . . . . . . . . . .
Flushing The Power Steering System 2A±11. . . . . .
Steering Wheel Free Play Inspection 2A±12. . . . . .
Front End Alignment Inspection and
Adjustment 2A±12. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main Data and Specifications 2A±16. . . . . . . . . . . . .
Special Tools 2A±17. . . . . . . . . . . . . . . . . . . . . . . . . .
Power Steering Unit 2A±18. . . . . . . . . . . . . . . . . . . . .
Power Steering Unit and Associated Parts 2A±18
Removal 2A±18. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation (4y2 Model) 2A±19. . . . . . . . . . . . . . . .
Installation (4y4 Model) 2A±19. . . . . . . . . . . . . . . .
Power Steering Unit Disassembled View 2A±20. .
Disassembly 2A±21. . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 2A±21. . . . . . . . . . . . . . . . . .
Reassembly 2A±21. . . . . . . . . . . . . . . . . . . . . . . . . .
Main Data and Specifications 2A±22. . . . . . . . . . .
Special Tools 2A±22. . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Steering Pump 2A±23. . . . . . . . . . . . . . . . . . . .
Power Steering Pump and Associated Parts 2A±23
Removal 2A±23. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 2A±23. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Steering Pump Disassembled View 2A±24
Disassembly 2A±24. . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 2A±25. . . . . . . . . . . . . . . . . .
Reassembly 2A±25. . . . . . . . . . . . . . . . . . . . . . . . . .
Main Data and Specifications 2A±27. . . . . . . . . . .
Transfer Gear Assembly 2A±28. . . . . . . . . . . . . . . . .
Transfer Gear Assembly and Associated
Parts 2A±28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal 2A±28. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 2A±28. . . . . . . . . . . . . . . . . .
Installation 2A±28. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Supplemental Restraint System Steering
Wheel & Column 2A±29. . . . . . . . . . . . . . . . . . . . . . .
Service Precaution 2A±29. . . . . . . . . . . . . . . . . . . .
SRS Connectors 2A±29. . . . . . . . . . . . . . . . . . . . . .
Inflator Module 2A±31. . . . . . . . . . . . . . . . . . . . . . . . . .
Inflator Module and Associated Parts 2A±31. . . . .
Removal 2A±31. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 2A±32. . . . . . . . . . . . . . . . . .
Installation 2A±32. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Steering Wheel 2A±33. . . . . . . . . . . . . . . . . . . . . . . . .
Steering Wheel and Associated Parts 2A±33. . . .
Removal 2A±33. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 2A±35. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Combination Switch 2A±36. . . . . . . . . . . . . . . . . . . . .
Combination Switch and Associated Parts 2A±36
Removal 2A±36. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 2A±38. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lock Cylinder 2A±40. . . . . . . . . . . . . . . . . . . . . . . . . . .
Lock Cylinder and Associated Parts 2A±40. . . . . .
Removal 2A±40. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 2A±42. . . . . . . . . . . . . . . . . . . . . . . . . . . .
System Inspection 2A±43. . . . . . . . . . . . . . . . . . . . .
Steering Column 2A±44. . . . . . . . . . . . . . . . . . . . . . . .
Steering Column and Associated Parts 2A±44. . .
Removal 2A±44. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection 2A±46. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 2A±48. . . . . . . . . . . . . . . . . . . . . . . . . . . .
System Inspection 2A±49. . . . . . . . . . . . . . . . . . . . .
Supplemental Restraint System Steering
Wheel & Column and Associated Parts 2A±50. . . .
Main Data and Specifications 2A±50. . . . . . . . . . .
Special Tools 2A±50. . . . . . . . . . . . . . . . . . . . . . . . . .

POWER±ASSISTED STEERING SYSTEM2A±11
4. Bleed the system. Refer to Bleeding the Power
Steering System
in this section.
5. Start the engine and check the fluid level. Add power
steering fluid if required. When the engine is at
normal operating temperature, increase engine
speed to 1500 rpm.
CAUTION: Do not leave shutoff valve fully closed
for more than 5 seconds, as the pump could become
damaged internally.
6. Fully close the shutoff valve. Record the highest
pressures.

If the pressure recorded is within 9300±9800 kPa
(1350±1420 psi), the pump is functioning within its
specifications.

If the pressure recorded is higher than 9800 kPa
(1420 psi), the valve in the pump is defective.

If the pressure recorded is lower than 9300 kPa
(1350 psi), the valve or the rotating group in the
pump is defective.
7. If the pump pressures are within specifications, leave
the valve open and turn (or have someone else turn)
the steering wheel fully in both directions. Record the
highest pressures and compare with the maximum
pump pressure recorded in step 6. If this pressure
cannot be built in either side of the power steering
unit, the power steering unit is leaking internally and
must be replaced.
8. Shut the engine off, remove the testing gauge.
9. Reconnect the pressure hose, check the fluid level
and make the needed repairs.
10. If the problem still exists, the steering and front
suspension must be thoroughly examined.
Maintenance
The hydraulic system should be kept clean and fluid level
in the reservoir should be checked at regular intervals and
fluid added when required. Refer to
Recommended
Fluids and Lubricants in General Information
section for
the type of fluid to be used and the intervals for filling.
If the system contains some dirt, flush it as described in
this section. If it is exceptionally dirty, the pump must be
completely disassembled before further usage. (The
steering unit cannot be disassembled.)
All tubes, hoses, and fittings should be inspected for
leakage at regular intervals. Fittings must be tight. Make
sure the clips, clamps and supporting tubes and hoses
are in place and properly secured.
Power steering hoses and lines must not be twisted,
kinked or tightly bent. Air in the system will cause spongy
action and noisy operation. When a hose is disconnected
or when fluid is lost, for any reason, the system must be
bled after refilling. Refer to
Bleeding the Power Steering
System
in this section.

Inspect belt for tightness.

Inspect pulley for looseness or damage. The pulley
should not wobble with the engine running.

Inspect hoses so they are not touching any other
parts of the vehicle.

Inspect fluid level and fill to the proper level.
Fluid Level
1. Run the engine until the power steering fluid reaches
normal operating temperature, about 55
C (130
F),
then shut the engine off.
2. Check the level of fluid in the reservoir.
3. If the fluid level is low, add power steering fluid as
specified in General Information to the proper level
and install the receiver cap.
4. When checking the fluid level after the steering
system has been serviced, air must be bled from the
system. Refer to
Bleeding the Power Steering
System
in this section.
Bleeding The Power Steering System
When a power steering pump or unit has been installed,
or an oil line has been disconnected, the air that has
entered the system must be bled out before the vehicle is
operated. If air is allowed to remain in the power steering
fluid system, noisy and unsatisfactory operation of the
system may result.
Bleeding Procedure
When bleeding the system, and any time fluid is added to
the power steering system, be sure to use only power
steering fluid as specified in General Information.
1. Fill the pump fluid reservoir to the proper level and let
the fluid settle for at least two minutes.
2. Start the engine and let it run for a few seconds. Do
not turn the steering wheel. Then turn the engine off.
3. Add fluid if necessary.
4. Repeat the above procedure until the fluid level
remains constant after running the engine.
5. Raise and support the front end of the vehicle so that
the wheels are off the ground.
6. Start the engine. Slowly turn the steering wheel right
and left, lightly contacting the wheel stops.
7. Add power steering fluid if necessary.
8. Lower the vehicle, set the steering wheel at the
straight forward position after turning it to its full steer
positions 2 or 3 times, and stop the engine.
9. Check the fluid level and refill as required.
10. If the fluid is extremely foamy, allow the vehicle to set
a few minutes, then repeat the above procedure.
Flushing The Power Steering System
1. Raise and support the front end of the vehicle off the
ground until the wheels are free to turn.
2. Remove the fluid return line at the pump inlet
connector and plug the connector port on the pump.
Position the line toward a large container to catch the
draining fluid.
3. While running the engine at idle, fill the reservoir with
new power steering fluid. Turn the steering wheel in
both directions. Do not contact or hold the steering
wheel to the wheel stops. This will cause the pump to
go to pressure relief mode, which may cause a
sudden fluid overflow at the reservoir.

3D±6REAR SUSPENSION
Inspection and Repair
Make necessary correction or parts replacement if wear,
damage, corrosion or any other abnormal condition are
found through inspection.
Check the following parts:

Coil spring

Insulator
Installation
1. Install coil spring and make sure that the coil spring is
installed in the proper position. Paint mark(1) should
be downward.
460RW001
2. Fit the end of the coil spring to the coil spring seat and
mount the coil spring on the rear axle case.
460RW004
3. Install the insulator on the coil spring. Jack up the axle
case gently with the top of the coil spring set to the
spring seat on the frame side.
460RW013
4. Install shock absorber and make sure that installed in
the proper position. (Refer to
Intelligent Suspension)
Tighten the nut lightly, then retighten it to the specified
torque after the vehicle is at curb height.
NOTE: When mounting shock absorber, be sure not to
use grease on bushings or any other nearby part.
Torque: 78 N´m (58 lb ft)
5. Install stabilizer bar.
Torque: 31 N´m (23 lb ft)
6. Install upper link with rubber plate and tighten fixing
bolt.
Torque: 137 N´m (101 lb ft)
7. Install breather hose.
8. Connect brake hose and bleed the brake system.
Refer to
Bleeding the Brake Hydraulic System in
Brake section.

3D±24REAR SUSPENSION
Inspection and Repair
Make necessary correction or parts replacement if wear,
damage, corrosion or any other abnormal condition are
found through inspection.
Check the following parts:

Coil spring

Insulator
Installation
1. Install coil spring and make sure that the coil spring is
installed in the proper position. Paint mark(1) should
be downward.
460RW001
2. Fit the end of the coil spring to the coil spring seat and
mount the coil spring on the rear axle case.
460RW004
3. Install the insulator on the coil spring. Jack up the axle
case gently with the top of the coil spring set to the
spring seat on the frame side.
460RW013
4. Install shock absorber and tighten the nut lightly, then
retighten it to the specified torque after the vehicle is
at curb height.
NOTE: When mounting shock absorber, be sure not to
use grease on bushings or any other nearby part.
Torque: 78 N´m (58 lb ft)
5. Install stabilizer bar at the stabilizer link.
Torque: 31 N´m (23 lb ft)
6. Install upper link with rubber plate and tighten fixing
bolt.
Torque: 137 N´m (101 lb ft)
7. Install breather hose.
8. Connect brake hose and bleed the brake system.
Refer to
Bleeding the Brake Hydraulic System in
Brake
section.

5C±1 POWER±ASSISTED BRAKE SYSTEM
AXIOM (Vehicles Produced Before July/31/2001)
BRAKES
POWER-ASSISTED BRAKE SYSTEM
CONTENTS
Service Precaution 5C±2. . . . . . . . . . . . . . . . . . . . . .
General Description 5C±2. . . . . . . . . . . . . . . . . . . . .
Diagnosis 5C±6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Diagnosis 5C±7. . . . . . . . . . . . . . . . . . . . . . .
Hydraulic Brakes 5C±10. . . . . . . . . . . . . . . . . . . . . . . .
Filling Master Cylinder Reservoir 5C±10. . . . . . . .
Deterioration of Brake Fluid 5C±10. . . . . . . . . . . . .
Leakage of Brake Fluid 5C±10. . . . . . . . . . . . . . . . .
Bleeding Brake Hydraulic System 5C±10. . . . . . . .
Flushing Brake Hydraulic System 5C±11. . . . . . . .
Brake Pipes and Hoses 5C±11. . . . . . . . . . . . . . . .
Brake Hose Inspection 5C±11. . . . . . . . . . . . . . . . .
Front Caliper Brake Hose 5C±12. . . . . . . . . . . . . . . .
Front Caliper Brake Hose and Associated
Parts 5C±12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal 5C±12. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 5C±12. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Axle Brake Hose 5C±13. . . . . . . . . . . . . . . . . . .
Rear Axle Brake Hose and Associated
Parts 5C±13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal 5C±13. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 5C±13. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brake Pipe 5C±14. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal 5C±14. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 5C±14. . . . . . . . . . . . . . . . . . . . . . . . . . . .
P & B (Proportioning and Bypass) Valve 5C±15. . . .
P & B (Proportioning and Bypass) Valve
Sectional View 5C±15. . . . . . . . . . . . . . . . . . . . . . . .
Removal 5C±15. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 5C±15. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main Data and Specifications 5C±16. . . . . . . . . . . . .
Brake Pedal 5C±17. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking Pedal Height 5C±17. . . . . . . . . . . . . . . . .
Checking Pedal Travel 5C±17. . . . . . . . . . . . . . . . .
Brake Pedal and Associated Parts 5C±18. . . . . . .
Removal 5C±18. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 5C±18. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stoplight Switch 5C±19. . . . . . . . . . . . . . . . . . . . . . . . .
Parts Location 5C±19. . . . . . . . . . . . . . . . . . . . . . . .
Removal 5C±19. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 5C±19. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main Data and Specifications 5C±20. . . . . . . . . . . . .
Fluid Reservoir Tank 5C±21. . . . . . . . . . . . . . . . . . . . .
Fluid Reservoir Tank and Associated Parts 5C±21Removal 5C±21. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 5C±21. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Master Cylinder Assembly 5C±22. . . . . . . . . . . . . . . .
Master Cylinder Assembly and Associated
Parts 5C±22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal 5C±22. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 5C±22. . . . . . . . . . . . . . . . . .
Installation 5C±23. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main Data and Specifications 5C±24. . . . . . . . . . .
Special Tools 5C±24. . . . . . . . . . . . . . . . . . . . . . . . . .
Vacuum Booster Assembly 5C±25. . . . . . . . . . . . . . .
Vacuum Booster Assembly and Associated
Parts 5C±25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal 5C±25. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 5C±26. . . . . . . . . . . . . . . . . .
Installation 5C±26. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exterior Components 5C±28. . . . . . . . . . . . . . . . . . . .
Exterior Components and Associated Parts 5C±28
Removal 5C±28. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 5C±29. . . . . . . . . . . . . . . . . .
Installation 5C±29. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Vacuum Booster Overhaul 5C±29. . . . . . . . . . . . . . . .
Vacuum Booster 5C±29. . . . . . . . . . . . . . . . . . . . . . .
Main Data and Specifications 5C±30. . . . . . . . . . . . .
Special Tools 5C±31. . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Disc Brake Pads 5C±32. . . . . . . . . . . . . . . . . . .
Front Disc Brake Pads Inspection 5C±32. . . . . . . .
Front Disc Brake Pads and Associated
Parts 5C±32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal 5C±33. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 5C±33. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Disc Brake Rotor 5C±35. . . . . . . . . . . . . . . . . . .
Inspection 5C±35. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing Brake Rotors 5C±35. . . . . . . . . . . . . . . .
Refinishing Brake Rotors 5C±35. . . . . . . . . . . . . . .
Front Disc Brake Caliper Assembly 5C±36. . . . . . . .
Front Disc Brake Caliper Assembly and
Associated Parts 5C±36. . . . . . . . . . . . . . . . . . . . . .
Removal 5C±37. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 5C±37. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Disc Brake Caliper 5C±39. . . . . . . . . . . . . . . . .
Front Disc Brake Caliper Disassembled
View 5C±39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly 5C±39. . . . . . . . . . . . . . . . . . . . . . . . . .

5C±3 POWER±ASSISTED BRAKE SYSTEM
The master cylinder contains two pistons that supply the
hydraulic pressure for a dual±circuit braking system. The
primary piston provides the fluid pressure to the front
brakes, while the secondary piston provides the fluid
pressure to the rear brakes. If the pressure is lost from
either system, the remaining system will function to stop
the vehicle.CAUTION:
1. The master cylinder is not repairable. If found
defective, it must be replaced as a complete
assembly.
2. If any hydraulic component is removed or
disconnected, it may be necessary to bleed all or
part of the brake system. (Refer to
Bleeding Brake
Hydraulic System
in this section.)
3. The torque values specified are for dry,
unlubricated fasteners.
4. Perform service operations on a clean bench free
from all mineral oil materials.
Brake Booster
331RS001
This booster is a tandem vacuum unit with a diaphragm
effective diameter 205mm (8.072 in) + 230mm (9.056 in).
In normal operating mode, with the service brakes in the
released position, the tandem vacuum booster operates
with vacuum on both sides of its diaphragms. When the
brakes are applied, air at atmospheric pressure is
admitted to both sides of the diaphragm to provide the
power assist. When the service brake is released, the
atmospheric air is shut off from both sides of the
diaphram. The air is then drawn from the booster through
the vacuum check valve to the vacuum source.CAUTION:
1. If any hydraulic component is removed or
disconnected, it may be necessary to bleed all or
part of the brake system.
2. The torque values specified are for dry,
unlubricated fasteners.
3. The vacuum booster is not repairable and must be
replaced as complete assembly.

5C±10
POWER±ASSISTED BRAKE SYSTEM
Hydraulic Brakes
Filling Master Cylinder Reservoir
CAUTION: Use only specified brake fluid. Do not
use any fluid which contains a petroleum base. Do
not use a container which has been used for
petroleum based fluids or a container which is wet
with water. Petroleum based fluid will cause swelling
and distortion of rubber parts in the hydraulic brake
system. Water mixed with brake fluid lowers the fluid
boiling point. Keep all fluid containers capped to
prevent contamination.
Always fill the master cylinder reservoir when the en-
gine is cold.
Never allow the brake fluid to come in contact with
the painted surfaces.
The master cylinder reservoir must be kept properly
filled to ensure adequate reserve and to prevent air
and moisture from entering the hydraulic system.
However, because of expansion due to heat ab-
sorbed from the brakes and the engine, the reservoir
must not be overfilled. The brake fluid reservoir is on
the master cylinder, which is located under the hood
on the left side of the cowl. Thoroughly clean reser-
voir cap before removal to avoid getting dirt into res-
ervoir. Remove the diaphragm. Add fluid as required
to bring level to the ªMAXº mark on the reservoir
tank. Use ªDOT 3º Hydraulic Brake Fluid. If the fluid
cap diaphragm is stretched, return it to the original
position before installing.
Deterioration of Brake Fluid
Using any other brake fluid than specified or brake fluid
with mineral oil or water mixed in will drop the boiling point
of brake fluid. It may, in turn, result in vapor lock or
deteriorated rubber parts of the hydraulic system. Be sure
to change the brake fluid at specified intervals.
If the rubber parts are deteriorated, remove all the system
parts and clean them with alcohol. Prior to reassembly,
dry the cleaned parts with air to remove the alcohol.
Replace all the hoses and rubber parts of the system.
Leakage of Brake Fluid
With engine idling, set shift lever in the neutral position
and continue to depress brake pedal at a constant pedal
application force.
Should the pedal stroke become deeper gradually,
leakage from the hydraulic pressure system is possible.
Perform visual inspection for any signs of leakage.
Bleeding Brake Hydraulic System
A bleeding operation is necessary to remove air from the
hydraulic brake system whenever air is introduced into
the hydraulic system. It may be necessary to bleed the
hydraulic system at all four brakes if air has been
introduced through a low fluid level or by disconnecting
brake pipes at the master cylinder. If a brake pipe is
disconnected at one wheel, only that wheel
cylinder/caliper needs to be bled. If the pipes aredisconnected at any fitting located between the master
cylinder and brakes, then the brake system served by the
disconnected pipe must be bled.
1. For 4±Wheel Antilock Brake System (ABS) equipped
vehicle, be sure to remove the ABS main fuse 60A
located at the relay and fuse box before bleeding air. If
you attempt to bleed air without removing the main
fuse, air cannot be let out thoroughly, and this may
cause damage to the hydraulic unit. After bleeding air,
be sure to replace the ABS main fuse back to its
original position.
2. Set the parking brake completely, then start the
engine.
NOTE: The vacuum booster will be damaged if the
bleeding operation is performed with the engine off.
3. Remove the master cylinder reservoir cap.
4. Fill the master cylinder reservoir with brake fluid.
Keep the reservoir at least half full during the air
bleeding operation
5. Always use new brake fluid for replenishment.
6. When replenishing the brake fluid reservoir, carefully
pour in the brake fluid to prevent air bubbles from
entering the brake system.
When the master cylinder is replaced or overhauled,
first bleed the air from the master cylinder, then from
each wheel cylinder and caliper following the
procedures described below.
Bleeding the Master Cylinder
7. Disconnect the rear wheel brake pipe (1) from the
master cylinder.
Check the fluid level and replenish as necessary. If
replenished, leave the system for at least one minute.
8. Depress the brake pedal slowly once and hold it
depressed.
9. Completely seal the delivery port of the master
cylinder with your finger, where the pipe was
disconnected then release the brake pedal slowly.
10. Release your finger from the delivery port when the
brake pedal returns completely.
11. Repeat steps 8 through 10 until the brake fluid comes
out of the delivery port during step 8.
NOTE: Do not allow the fluid level in the reservoir to go
below the half±way mark.
12. Reconnect the brake pipe (1) to the master cylinder
and tighten the pipe.
13. Depress the brake pedal slowly once and hold it
depressed.
14. Loosen the rear wheel brake pipe (1) at the master
cylinder.
15. Retighten the brake pipe, then release the brake
pedal slowly.
16. Repeat steps 13 through 15 until no air comes out of
the port when the brake pipe is loosened
NOTE: Be very careful not to allow the brake fluid to come
in contact with painted surfaces.

5C±11 POWER±ASSISTED BRAKE SYSTEM
330RW012
17. Bleed the air from the front wheel brake pipe
connection (2) by repeating steps 7 through 16.
Bleeding the Caliper
18. Bleed the air from each wheel in the order listed
below:

Right rear caliper or wheel cylinder

Left rear caliper or wheel cylinder

Right front caliper

Left front caliper
Conduct air bleeding from the wheels in the above
order. If no brake fluid comes out, it suggests that air
is mixed in the master cylinder. In this case, bleed air
from the master cylinder in accordance with steps 7
through 17, and then bleed air from the caliper or
wheel cylinder.
19. Place the proper size box end wrench over the
bleeder screw.
20. Cover the bleeder screw with a transparent tube, and
submerge the free end of the transparent tube in a
transparent container containing brake fluid.
21. Pump the brake pedal slowly three (3) times
(once/sec), then hold it depressed.
22. Loosen the bleeder screw until fluid flows through the
tube.
23. Retighten the bleeder screw.
24. Release the brake pedal slowly.
25. Repeat steps 21 through 24 until the air is completely
removed.
It may be necessary to repeat the bleeding procedure
10 or more times for front wheels and 15 or more
times for rear wheels.
26. Go to the next wheel in the sequence after each wheel
is bled.
Be sure to monitor reservoir fluid level.
27. Depress the brake pedal to check if you feel
ªsponginessº after the air has been removed from all
wheel cylinders and calipers.
If the pedal feels ªspongyº, the entire bleeding
procedure must be repeated.28. After the bleeding operation is completed on the each
individual wheel, check the level of the brake fluid in
the reservoir and replenish up to the ªMAXº level as
necessary.
29. Attach the reservoir cap.
If the diaphragm inside the cap is deformed, reform
it and install.
30. Stop the engine.
Flushing Brake Hydraulic System
It is recommended that the entire hydraulic system be
thoroughly flushed with clean brake fluid whenever new
parts are installed in the hydraulic system. Approximately
one quart of fluid is required to flush the hydraulic system.
The system must be flushed if there is any doubt as to the
grade of fluid in the system or if fluid has been used which
contains the slightest trace of mineral oil. All rubber parts
that have been subjected to a contaminated fluid must be
replaced.
Brake Pipes and Hoses
The hydraulic brake system components are
interconnected by special steel piping and flexible hoses.
Flexible hoses are used between the frame and the front
calipers, the frame and rear axle case and the rear axle
and the rear calipers.
When the hydraulic pipes have been disconnected for
any reason, the brake system must be bled after
reconnecting the pipe. Refer to
Bleeding the Brake
Hydraulic System
in this section.
Brake Hose Inspection
The brake hose should be inspected at least twice a year.
The brake hose assembly should be checked for road
hazard, cracks and chafing of the outer cover, and for
leaks and blisters. Inspect for proper routing and
mounting of the hose. A brake hose that rubs on
suspension components will wear and eventually fail. A
light and mirror may be needed for an adequate
inspection. If any of the above conditions are observed on
the brake hose, adjust or replace the hose as necessary.
CAUTION: Never allow brake components such as
calipers to hang from the brake hoses, as damage to
the hoses may occur.