Service Procedure

1. Open the hood and connect a battery charger to the battery.





2. Remove the brake master cylinder reservoir cap and filter (Figure 1).

3. Using a suction gun, remove the old brake fluid from the brake master cylinder reservoir.

4. Fill the master cylinder reservoir with new DOT 4 brake fluid (P/N A000989080701).

5. Fill a pressure bleeder with DOT 4 brake fluid (P/N A000989080701).

CAUTION:
DO NOT use any other types of brake fluid in the pressure bleeder. Use only (P/N A000989080701) DOT 4 brake fluid. Other brands of DOT 4 fluid may not meet the specifications.





6. Connect the pressure bleeder to the master cylinder reservoir (Figure 2).

7. Turn on the pressure bleeder and set the pressure level to 30 psi (2 bar).

8. Connect and setup the DRBIII using the following procedure:

a. Connect the Multiplexer (9043) to the data link connector located next to the left kick panel.

b. Insert the Sprinter Data Card (CH9087) into the DRBIII data card port.

c. Connect the DRBIII to the Multiplexer.

d. Place the ignition key in the "RUN" position.

e. Allow the DRBIII to boot up and then press the "YES" key to get to the "Main Menu."

f. Select "DRB Standalone" from the main menu and then press the "Enter" button.

g. Select "1998 - 2006 Diagnostics" and then press the "Enter" button.

h. Select "2002 - 2006 Sprinter" and then press the "Enter" button.
i. Read warnings on the DRBIII screen and then press the "Enter" button.

j. Select "System Select" and then press the "Enter" button.

k. The DRBIII screen will show the ESP/ABS Module display. Press the "Enter" button.

l. Select "Miscellaneous Functions" and then press the "Enter" button.

m. Select "Exceptional Bleeding" and then press the "Enter" button.
n. Follow the screen prompts to bleed each wheel.

NOTE:
Bleed the wheels in the order shown on the DRBIII screen.

9. Position the DRBIII so that it can be accessed while the vehicle is raised on the hoist.

10. With an assistant in the drivers seat, raise the vehicle on an appropriate hoist.





11. For 3500 series vehicles, temporarily install a plastic tie strap so that the load sensing proportioning valve arm is held against the proportioning valve (Figure 4).





12. Connect a bleed bottle to the right rear brake caliper bleeder screw (Figure 3).

13. Using the DRBIII, activate the wheel being bled and follow the screen prompts on the DRBIII.

NOTE:
The assistant in the vehicle must pump the brakes during the bleed procedure.

NOTE:
Each time a caliper is bled, approximately 13.5 oz. (400 ml) of brake fluid should flush through the system.

14. Repeat Steps 12 and 13 on the other three brake calipers in the order listed on the DRBIII screen.

15. Repeat Steps 12 through 14 four (4) additional times.

16. For 3500 series vehicles, remove and discard the plastic tie strap from the load sensing proportioning valve (Figure 4).

17. Lower the vehicle from the hoist.

18. Turn the ignition key to the "OFF" position.

19. Disconnect the pressure bleeder from the master cylinder reservoir.

20. Disconnect the battery charger from the vehicle.

21. Install the master cylinder reservoir fill filter.

22. Fill the master cylinder with Mopar DOT 4 brake fluid (P/N A000989080701) and install the brake master cylinder reservoir cap.

23. Verify proper brake operation.