Warning: Liquid is poisonous. Rinse the affected parts with copious amounts of cold running water and seek immediate medical attention if it gets into the mouth or eyes. Some types of fluid are flammable and may ignite on contact with hot components. Take appropriate fire safety measures. The liquid is aggressive to paint and plastics - if it comes into contact with such surfaces, immediately wash off the liquid with plenty of water. In addition, the liquid is hygroscopic (absorbs moisture from the air) - old fluid may be contaminated with water and unusable. When topping up or replacing fluid in the system, use the recommended type of fluid from a freshly opened sealed container.
1. Correct functioning of the hydraulic system is possible only if its components are free from air. Bleed the system to remove air.
2. During the bleeding procedure, add only clean, fresh brake fluid of the type specified in the Specifications. Never reuse liquid.
3. If there is any doubt about the type of fluid filled into the system, flush the system with clean fluid and replace all seals.
4. If part of the liquid has leaked out of the system or air has entered it, find and eliminate the cause of this, and only then proceed with pumping.
5. The bleed valve is located on the right side of the clutch housing (see illustration). To gain access, apply the handbrake, then jack up the front of the vehicle and support it on axle stands.
6. Make sure all tubes and hoses are securely attached and the bleeder valve is closed. Clean the area adjacent to the fitting.
7. Unscrew the cap of the feed tank of the main cylinder (Clutch hydraulic system and brake hydraulic system share a common supply reservoir) and bring the liquid level in it to the upper line («MAX»). Screw on the cap and be sure to keep the fluid level at least above the bottom line («MIN») throughout the procedure, otherwise air will again enter the system.
8. There are a number of tools available for one person to bleed the hydraulic system. It is recommended to use one of these kits, as they greatly simplify the work and also reduce the risk of air and fluid escaping from the system being drawn back into the system. If such a device is not available, use the basic bleeding method (for two people), detailed below.
9. If a tool is used, prepare the vehicle as described above and follow the kit manufacturer's instructions. The procedure may vary slightly depending on the type of device used, its main course is also described below.
Pumping - the main method (for two people)
10. Prepare a clean glass reservoir, a suitable length of plastic or rubber tubing that fits snugly over the bleed screw and ring wrench. You will need the help of a second person.
11. Remove the dust cap from the bleeder fitting and fit the tube prepared for bleeding and a wrench onto the fitting. Immerse the other end of the plastic tube in the brake fluid previously poured into the reservoir.
12. Make sure the master cylinder reservoir is filled and keep the fluid level in it above the line «MIN» throughout the entire procedure.
13. Have an assistant depress the clutch pedal several times to increase pressure, then depress it again and hold it in that position.
14. Open the bleed valve (about one turn). When fluid stops flowing out of the fitting, clamp it and ask an assistant to slowly release the pedal. Check the fluid level in the reservoir.
15. Repeat the steps described in points 13 and 14 until the escaping fluid is free of air bubbles. If the master cylinder reservoir was empty before bleeding, take approximately five seconds between bleeding cycles to allow the cylinder bore to fill.
16. When priming is complete, securely clamp the fitting, remove the tube and wrench from it, and install the dust cap. Do not overtighten the fitting.
Bleeding with non-return valve tool
17. These devices are a tube with a non-return valve that prevents air and fluid that have left it from being drawn back into the system. Some kits also include a transparent container.
18. Push the tube onto the bleed valve and open it. Depress the clutch pedal slowly and smoothly, then release it slowly. Repeat this action until the escaping fluid is free of air bubbles.
19. Remember to keep the fluid level in the reservoir above the line «MIN».
Pumping under pressure
20. These devices are powered by compressed air contained in the spare wheel chamber. However, the air pressure must first be reduced (see the instructions supplied with the tool).
21. Attach the container filled with brake fluid to the master cylinder supply reservoir and to the spare wheel. Bleed by opening the fitting and draining the fluid until it is free of bubbles.
22. This method has advantages because a large amount of liquid in the installed reservoir prevents air from entering the main cylinder during pumping.
All Methods
23. After priming, rinse off spilled liquid, securely clamp the fitting and install its dust cap.
24. Check the brake fluid level in the master cylinder reservoir and top up if necessary.
25. Remember that the brake fluid drained from the system is not suitable for reuse.
26. Check the elasticity of the clutch pedal. If dips are felt during its movement, there is still air in the system and further pumping is required. If re-priming is not satisfactory, the master or release cylinder seals may be worn.
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