Cobalt 2006-2008, G5 2007

Hydraulic System

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Bleeding



Manual Bleeding
  1. Before servicing the vehicle, refer to the Precautions Section.
    WARNING
    Do not reuse the fluid that has been bled from a system in order to fill the clutch master cylinder reservoir.


    NOTE
    Maintain the fluid level in the clutch reservoir to the top step with DOT 3 hydraulic fluid.

  2.  
  3. Clean dirt and grease from the cap in order to ensure that no foreign substances enter the system.
  4.  
  5. Attach a hose to the bleeder port on the clutch actuator assembly. Submerge the other end of the hose in a container of DOT 3 hydraulic fluid.
  6.  
  7. Depress the clutch pedal quickly to the full depressed position.

    Click image to see an enlarged view

    Fig. Push the clip in order to move the clutch line into the bleed position

  8.  
  9. Push the clip in order to move the clutch line into the bleed position.
  10.  
  11. Move the clutch line into the normal position ensuring that the clip returns.
  12.  
  13. Lift the clutch pedal to the up stop position and hold for 5 seconds.
  14.  
  15. Repeat steps 3-6 until air is purged from the clutch system.
  16.  

Vacuum Bleeding
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Verify that all the hydraulic lines are dry and secure.
  4.  
  5. Clean dirt and grease from the reservoir cap in order to ensure that no foreign substances enter the system.
  6.  
  7. Remove the reservoir cap.
  8.  
  9. Fill the reservoir using DOT 3 hydraulic fluid.
    WARNING
    Brake fluid will deteriorate the rubber on the adapter, use a clean shop towel to wipe away all fluid after each use.

  10.  
  11. Install a vacuum pump such as adapter J 43485 and pump J 35555 to the reservoir.
  12.  
  13. Hold the adapter to position while applying 51-68 kPa (15-20 hg) of vacuum.
  14.  
  15. Remove the adapter and refill the reservoir
  16.  
  17. Fully depress the clutch pedal cycling the pedal for 30 seconds.
  18.  
  19. Lift the clutch pedal to the up stop position and hold for 30 seconds.
  20.  
  21. Repeat steps 4-9 until all air is removed from the clutch system.
    CAUTION
    Do not start the engine while the transaxle is engaged, only while in the neutral position. This vehicle is equipped with a Concentric Slave Cylinder (CSC) and will move if started in gear.

  22.  
  23. Place the vehicle into the neutral position and start the engine.
  24.  
  25. Pump the clutch pedal until firm.
    CAUTION
    The clutch and braking systems are integrated into one reservoir. The brake may be soft when first applying.

  26.  
  27. Pump the brake pedal until firm.
  28.  
  29. If needed, add additional hydraulic fluid.
  30.  
  31. Road test the vehicle to ensure proper operation.
  32.  

 
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