Opel CORSA-E RALLY 2022 Manual page 138

TECHNICAL DOCUMENTATION
5. Draining the reservoir

Remove the brake fluid reservoir

Drain the brake fluid reservoir
Using a clean syringe.
6. Filling the reservoir
Caution: Use only clean fluid free from bubbles. Avoid any introduction of impurities into the
hydraulic system.
Caution: Use only approved and recommended hydraulic fluid: DOT4.

Fill the brake fluid reservoir

Bleed the primary braking circuit.
7. Bleeding the braking circuit
Caution: Two operators are necessary.
Caution: During the bleed operations, take care to maintain the level of brake fluid in the reservoir by
topping it up.
Notice: At the beginning of the bleeding process, pressurize the fly-off-handbrake (FOH) repeatedly
to ensure that there is no air in the FOH-cylinder.

Fill the brake fluid reservoir

Connect a transparent pipe on the bleed screw.

Repeatedly press on the brake pedal to pressurize the braking circuit.

Keep the brake pedal pressed.

Open the bleed screw (The brake pedal should descend and the pressure should drop).

Hold the pedal fully down.

Close the bleed screw.

Allow the brake pedal to return naturally.

Wait 2 seconds for the fluid to arrive in the master-cylinder.

Repeat the operation until the fluid running out is clean and free from air bubbles.
8. Checks

At the end of the bleed process, check the brake fluid level and top up if necessary.

Start the engine (To establish the vacuum in the brake servo ).

Check the travel and the feel of the brake pedal and fly-off-handbrake:
o Excessive travel
o Sponginess
o Lack of resistance.

If the travel of the brake pedal or fly-off-handbrake is excessive:
o Check the braking circuit (No leaks )
o Check the clutch circuit (No leaks )

If there are no leaks, repeat the procedure for bleeding the braking circuit.
 Road test the vehicle(if necessary).
9. Additional operations

Refit the wheels (see Page 134)
V2, 02/2022
[1] cap [a]
[1] as much as possible;
[1] to its maximum capacity[at
[1] to its maximum capacity.
Page 139 of 293
a].