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Another ABS Brake Question

294 views 9 replies 5 participants last post by  ian29gte  
#1 ·
Let me start by saying I’ve spent the past several days digging through nearly 20 years of posts on the AC Delco ABS systems, both here and on TLF. At this point, I feel like I’m fully immersed in the problems and nuances of this setup.

I’m also fortunate enough to have one of Ian’s big brake kits sitting unopened in the box. That will always be my last resort, but before I go down that route, I want to see if I can get the Delco system working properly, or at least working as close to how it was intended as possible.

Where I’m at now:

  • Car is new to me (had it a few months) and I’ve been working through various issues.
  • I’ve had an intermittent flashing ABS light since day one. On my last 50-mile drive, the light didn’t come on at all.
  • When hooked up to Espritmon, if I pump the brakes I can sometimes trigger the ABS light and get error 62 (low accumulator). I understand this can be caused by the pressure switch or the accumulator itself, and I know how scarce the switches are.
  • My plan is to try cleaning the switch first. I’m waiting on a crows foot wrench so I can remove it carefully—I don’t want to risk damaging it since replacements aren’t exactly available at AutoZone.
  • After depressurizing the system, the pump runs for ~37 seconds before cutting off. I also get about 2–4 pedal pumps before the pump cycles, which seems to be within the “normal” range.
  • Today, I depressurized the system and opened the reservoir for the first time. The rear reservoir looked cloudy (fine air bubbles or maybe contamination?), while the front reservoir looked normal/clear.
My questions:

  1. Could bad/contaminated fluid in the rear reservoir cause issues that would trigger error code 62?
  2. I plan to bleed the brakes. I’ve always used a power bleeder on my other cars, but obviously that won’t work with this system. I’ll be using a check-valve bleeder for the process. The manual states that the rears are bled under pressure. The service manual doesn’t explicitly state that the reservoir cap must be refitted before bleeding the rear brakes, does it matter? Is it okay to pressurize the system with the reservoir cap off, or will that just make a mess?
As always, thanks in advance for the support.
 
#2 ·
I've bled the rear brakes on an S4s, it requires the engine to be running and the pedal to be pressed down (not pumped) because that is what actuates the pump to apply pressure to the rears.

YES, the reservoir needs to be capped. It is pressurized.

Def. replace ALL the fluid in the brake system. If you can actuate the ABS (by keeping 2 wheels on gravel, lets say) DO IT. Then bleed again.


You can tell why I buy the large bottles of brake fluid... 🤪
 
#4 ·
Thanks for the info, figure there is a lot of expertise out there with these cars and just trying to tap into it.

On the rear brakes, my understanding is: with the system pressurized, open the bleed nipple and let it run for ~15 seconds (as the manual says), then depressurize the system, open the reservoir, and top it up as needed; repeat until system runs clear.

Is that the correct sequence? I’m guessing this is why the whole process takes a while to get through.
 
#5 ·
I own two S4 Esprits, and have some experience with the system by now, having bled them both many times. If you go on the lotus esprit world website, they have a step-by-step process to bleed them, there’s many steps involved, but none of it is particularly difficult. Depending on the age of your accumulator, I would probably start by replacing that, many people say that after 6 to 8 years, they lose their pressure. I don’t find that to be true, But if yours is over 10 years, it seems like a good place to start. Removing and cleaning your pressure switch is also a great idea, but fortunately, if you need one, the one that you get through Lotus marques is very popular, and the only replacement solution these days.
 
#6 ·
The reservoir is not pressurised but if you leave the cover off there's a good chance brake fluid can be ejected during the brake being operated. Error 62 is most likely caused by the accumulator losing its precharge pressure. Getting air out of the fluid can be a long process on the Delco Morraine system and be prepared to have to pressurise and depressurise the system a few times to do it. Do not pressurise the system when there is air in the fluid in the reservoir.
 
#9 ·
Quick update, pulled the brake switch and cleaned it out. Did not seem clogged and did not notice anything coming out. I did notice that in the threaded hole for the switch there was some what looked like a bit of dirt or debris, not much but after 30 years who knows. New accumulator has shipped and should be here in the next few days. While waiting for the accumulator I figured I would just install the cleaned brake pressure switch and see if I still had the low accumulator error. Threaded the switch back in and immediately notices one of the two o-rings split. When I initially removed the switch, the two 0-rings were not a tight fit but thought I would give it a try but with no luck, guess they are a bit old. Have a variety of EPDM o-rings being shipped to me now.

Since it is tough to buy just a couple of o-rings I should have plenty of extra if anyone needs any. Tough to find the right size EPDM o-rings, local parts store did not really have any selection at all.

Good new is that since I have a few days with the car on the lift, I took my OZ Futura's off and am having them all refinished!