SAFARI BSVI - SERVICE MANUAL

BRAKES (EPB) 21 B. ABS SECONDARY CIRCUIT BLEEDING PROCEDURE (USING DIAGNOSTIC TOOL) The secondary circuit bleeding has to be done only for ABS vehicles and only for the below mentioned specific cases. a. If the customer has not changed the brake fluid for 5 years or more. b. If the brake pedal becomes spongy after ABS intervention/operation. CAUTION  Do not spill brake fluid on the vehicle, it may damage the paint, if the brake fluid does contact the paint, wash it off immediately with water.  Make sure no dirt or other foreign matter is allowed to contaminate the brake fluid. NOTE  Always use the brake fluid recommended in the specification list.  Do not reuse the drained fluid.  Entire bleeding operation should be done with ENGINE ON (running).  The reservoir on the master cylinder must be at the Max (upper) level mark at the start of bleeding procedure and checked after bleeding each brake caliper and have to be topped up as required. 1. Bleed the brake fluid manually as mentioned in the previous procedure “Brake Bleeding Procedure”. 2. Connect the Diagnostic tool and select “Repair Bleed” in the ABS ECU section of the tool. 3. Open the bonnet. 4. Open the reservoir cap and pour brake fluid till the lower edge of the filler neck. 5. Connect the bleed tube to the rear left caliper bleed screw and place the other end submerged in a transparent container containing sufficient brake fluid. 6. Click on the start button on the diagnostic tool to start the process. 7. Depress the pedal completely, holding it depressed. 8. Open the rear left caliper bleed screw . 9. Press the OK button to start bleeding the rear left wheel. 10.The tool will start bleeding the rear left wheel. 11.When the tool finishes bleeding the rear left wheel, pump the brake pedal until the fluid flowing out is free of air bubbles; Close the bleed screw, Press “OK” to continue bleeding the Front Left wheel. 12.Continue to bleed the remaining wheels; the diagnostic tool will follow the following sequence. CAUTION  At all times during the bleeding process, it has to be ensured that the fluid level in the reservoir does not drop below minimum.  Allow a gap of 10 minutes before re-trying to bleed the system using diagnostic tool. This is needed to allow the solenoids to cool down. 13.After the bleeding sequence is completed remove the bleed tube and place the dust cap on the bleed screw. 14.Ensure that the bleed screw is tightened to the recommended torque. NOTE After the bleeding is done check for any leaks in the bleed screw by applying the brake pedal hard.