Electronic Stability Control (ESC)

BRAKE BLEEDING AT THE DEALERS (WORKSHOPS)

NOTE:
In section 1.1 to 4.3, the bleeding procedure is described without bleed machine. Ensure that always sufficient brake fluid is in the reservoir. Using a bleed machine simplifies these sections analog to section 5 "Brake fluid renewal". Then the bleeding process should be accompanied by additional pedal strokes (about 5x per wheel circuit) with the connected bleed machine.

1. System bleeding after replacement of TMC.

1.1 Preparation of actuation
a. Connect new TMC to booster assembly
b. Assemble reservoir to TMC.
c. Assemble brake tubes to TMC brake line ports.
d. Fill reservoir with new DOT4 brake fluid.

1.2 Conventional bleeding of brake system.
a. Connect bleeder bottle tube to FL caliper bleeder screw.
b. Actuate brake pedal with a pedal force of 150N to 200N.
c. Open bleeder screw until pressure is released, close bleeder screw, then release brake pedal.
d. After pedal release wait 2s until brake fluid is flown into the master cylinder.
e. Repeat this procedure till clear, bubble free brake fluid streams out.

Lead value: 10 to 20 times.

NOTE:
Watch brake fluid level in reservoir and refill if necessary (mind the pad wear).
According 1.2 repeat procedure for caliper FR, RL and RR.
(Only for ESC vehicles). When manual bleeding in IG ON.
Warning Lamp is ON due to malfunction of pressure sensor
Erase Warning Lamp using Hi-scan tool.
There is No problem when IG is OFF

1.3 Vehicle disconnection
a. Fill reservoir to "MAX" level and mount reservoir cap (mind pad wear)
b. Start engine to generate vacuum in the booster.
c. Check brake pedal travel and pedal feeling.

NOTE:
If the pedal travel is too long after the bleeding, check the brake system for leaks, or if O.K., repeat procedure 1.2 (only for ESC vehicles) Trim the pressure sensor(s) via diagnose.

d. Remove bleeder hoses and retighten wheel bleeder screws to correct torque.

Tightening torque: 7-13 N.m (70-130 kg.cm, 5-9 lb-ft)

2. System bleeding after replacement of one (both) TMC pressure sensor(s)
(Only for ESC vehicles)

2.1 Preparation of actuation

1)
a. Assemble new pressure sensor(s) to TMC

NOTE:
After assembling, trim the new pressure sensor(s) via diagnosis.

b. Fill reservoir with new DOT4 brake fluid.

2.2 Bleeding conventional brake system
See section 1.2

2.3 Vehicle disconnection according to 1.3

3. Bleeding brakes after replacement of the Hydraulic Control Unit (HCU)

NOTE:
The repair part HCU is completely filled

3.1 Vehicle preparation

1)
a. Connect bleeder bottle tube to bleed screws of FL and RL caliper and open them,
b. Actuate the brake pedal > 60 mm and secure it by using a pedal support. This closes the TMC central valves and prevents fluid flowing out of the opened brake system.
c. Close FL and RL caliper bleeder screws and remove bleeder bottle.
d. Remove defective HCU.

NOTE:
Remove brake tubes which lead from the HCU to the TMC first and close open ports of the HCU with protection caps immediately. Then remove brake tubes from HCU to the brakes and close these ports of the HCU with protection caps, too.

e. Install new HCU

NOTE:
The new repair part HCU is totally pre-filled. To keep the brake fluid inside the HCU, remove port protection caps of the brake circuit connections first and assemble these brake tubes. When all brake circuits are connected, remove port protection caps of TMC ports of HCU and connect TMC tubes to HCU.

f. Remove pedal support.
g. Remove fluid reservoir cap and fill reservoir to "MAX" with new DOT 4 brake fluid.
h. Lift vehicle or use inspection pit.

3.2 Bleeding conventional brake system
See section 1.2

3.3 Vehicle disconnection according to 1.3

4. Brake bleeding after caliper replacement.

4.1 Vehicle preparation

1)
a. Connect bleeder bottle tube to bleed screw of FL and RL caliper and open them.
b. Actuate the brake pedal > 60 mm and secure if by using a pedal support. This closes the TMC central valves and prevents fluid flowing out of the opened brake system.
c. Close FL and RL caliper bleeder screws and remove bleeder bottle.
d. Replace defective caliper with a new one.
e. Remove fluid reservoir cap and fill reservoir to "MAX" with new DOT 4 brake fluid.
4.2 Bleed procedure
Only the new caliper has to be bled according to the conventional bleeding method. (See section 1.2)
4.3 Vehicle disconnection according to 1.3

5. Brake fluid renewal

5.1 Vehicle preparation

1)
a. Connect bleeder unit to brake fluid reservoir.
Fill pressure max. 3 bar.
b. Lift vehicle

5.2 Bleed procedure

2)
a. Connect bleeder bottle tube to FL caliper bleed screw and open it.
b. Leave screw open until new, clear, bubble free fluid is observed in tube.
c. Close bleed screw.
d. Repeat above procedure for the remaining wheel calipers.

5.3 Vehicle disconnection

3)
a. Remove the bleeder unit.
b. Act according to 1.3