Antilock Brake System Automated Bleed Procedure With Pressure

Notice: Use only DOT 3 brake fluid from a clean, sealed container. Do not use any fluid from a container which is wet with water. Do not use DOT 5 silicone fluid.

Notice: Pressure bleeding equipment must be of the diaphragm type. It must have a rubber diaphragm between the air supply and the brake fluid to prevent air, moisture, and other contaminants from entering the hydraulic system.

Important: Prior to bleeding the rear brakes, the rear displacement cylinder pistons must be returned to the top most position or HOME. To return the pistons to home (top most position), use the PDT, or equivalent to perform SPECIAL TEST, RUN ABS MOTORS, PISTON UP-HOME. This test will run the piston to the top of their travel.

1. Clean brake fluid reservoir cap and area around cap. Remove cap.
2. Fill the master cylinder reservoir with clean brake fluid and keep reservoir at least one half full during the bleed operation.
3. Install the bleeder adaptor SA9150BR (or equivalent) to the brake fluid reservoir.
4. Connect pressure bleeder to adapter.
5. Charge pressure bleeder equipment to 207-242 kPa (30-35 psi).



6. Bleed brake modulator assembly:

6.1.	Attach a transparent tube over the rear modulator assembly bleeder valve and allow the tube to hang submerged in a clean container partially filled with brake fluid.

6.2.	Slowly open bleeder valve 1/2 to 3/4 turn and allow fluid to flow until no air is seen in the fluid.

6.3.	Close the bleeder valve.

Tighten:
7 N·m (62 lb in)

6.4.	Repeat steps 6.1 to 6.3 for the front modulator assembly bleeder valve.




7. Bleed the calipers (and wheel cylinders if vehicle has rear drum brakes) in the following order.

-	A. Right rear

-	B. Left rear

-	C. Right front

-	D. Left front

7.1.	Attach a transparent tube over the caliper assembly bleeder valve and allow the tube to hang submerged in a clean container partially filled with brake fluid.

7.2.	Open bleeder valve 1/2 to 3/4 turn and allow fluid to flow until no air is seen in the fluid.

7.3.	Close bleeder valve.

Tighten:
11 N·m (97 lb in)

Tighten:
7.5 N·m (66 lb in)

Important: To assist in freeing entrapped air, tap lightly on caliper casting with a rubber mallet.

7.4.	Repeat step 7.1 through 7.3 for each wheel in the order specified above, until no air is present in any brake lines.

8. Check the brake pedal for firm constant feel and travel both with the engine Off (ignition On) and with the engine running.

If pedal feel is firm and constant and travel is not excessive, go to step 9.

If pedal feel is not firm and constant or travel is excessive.

8.1.	Use PDT, or equivalent to RUN ABS MOTORS, PISTONS UP-HOME and PISTONS DOWN-REL two times.

8.2.	Use scan tool, home pistons.

8.3.	Start engine and let it run for two seconds after the ABS light goes out.

8.4.	Turn Off engine.

8.5.	Repeat steps 8.3 and 8.4 nine more times.

8.6.	Bleed entire brake system again.

9. Check for leaks with engine running and brakes applied.
10. Road test the vehicle.

10.1.

Make several normal (non-ABS) stops from a moderate speed.

10.2.

Make one to two ABS stops from a higher speed at approximately 80 km/h (50 mph).

11. After road testing the vehicle, it is recommended that the system be bled again following the steps 1 through 7 and then inspected again. If after inspection the pedal feels firm and constant and pedal travel is not excessive, system is properly bled.

Antilock Brake System Automated Bleed Procedure Without Pressure

Tools Required

Important: If a pressure bleeder is not available, a manual pedal method can be used with the aid of an assistant. The manual pedal method will consist of the assistant opening and closing bleeder screws or actuating the brake pedal. The manual pedal method will still require the use of a Scan tool to properly bleed the brake system.

The alternate automated brake bleed procedure is used on DBC7 ABS systems. This procedure uses a Scan tool to cycle the solenoid valves and run the pump in order to purge air from the secondary circuits. The automated bleed procedure opens the secondary circuits, then allows trapped air in the brake pressure modulator valve (BPMV) to flow outwards to the individual corners, where the air is purged from the system.

Important: The alternate automated brake bleed procedure is required when one of the following has occurred:

1. Inspect the battery for full charge. Charge the battery or repair the charging system if the battery is not fully charged.
2. Connect a scan tool to DLC connector. Check and repair current or history DTCs prior to performing any brake system bleeding.
3. Inspect for visual damage or leaks, repair as needed.
4. Fill the master cylinder reservoir with clean brake fluid. Keep the reservoir at least half full during the entire bleed procedure.

Important: Use only DOT 3 brake fluid. Brake fluid is corrosive. Take care not to allow brake fluid to contact any painted surfaces. Wipe off and clean painted surface immediately if contact is made.

5. Turn the ignition switch to RUN, with the engine OFF.
6. Raise the vehicle on a suitable support.
7. Connect the scan tool and establish communication with ABS system by following these steps:

7.1.	Select DIAGNOSTIC

7.2.	Select the appropriate model year

7.3.	Select SATURN (not passenger car)

7.4.	Select CHASSIS

7.5.	Select CAR LINE - Z

7.6.	Select CONTINUE

The ABS braking is not available when ABS/TCS lamps are illuminated statement will appear on the screen.

7.7.	Select SPECIAL FUNCTIONS

7.8.	Select AUTOMATED BLEED

The Connect Required Brake Bleed Equipment statement will appear the on screen. Disregard the statement for this alternate automated bleed procedure.

1. With the bleeder screws in the closed position, Select CONTINUE to start the bleed procedure.

The first part of the automated bleed procedure will cycle the pump for 60 seconds. After cycling the pump, the scan tool will go into a cool-down mode for 180 seconds, a 3 minute timer will be displayed. The automated bleed procedure will not continue until the timer has expired, and it cannot be overridden.

Important: For the following steps, the assistant should be applying and holding the brake pedal, or opening and closing the designated bleeder screw when appropriate.

2. The scan tool will instruct to open the right rear bleeder screw first.

2.1.	Before starting the bleed procedure, assistant should slowly stroke, apply, and hold the brake pedal.

2.2.	Once the brake pedal is in a held position, press START on the scan tool and open the bleeder screw simultaneously.

2.3.	When the brake pedal reaches the floor, close the bleeder screw. The assistant can now release the brake pedal.

2.4.	The assistant should again stroke, apply, and hold the brake pedal.

2.5.	Open the bleeder screw until the brake pedal reaches the floor. Then close the bleeder screw.

2.6.	Repeat this procedure as many times as possible during the scan tool timed program or until all air is removed.

2.7.	Once the scan tool is done cycling the designated brake corner, ensure that the bleeder screw is closed prior to moving on to the next corner.




3. Repeat step 2 with the scan tool for the remaining brake corners in the following order:

3.1.

Left rear

3.2.	Right front

3.3.	Left front

Important: The assistant should continue to apply and hold the brake pedal, or open and close the designated bleeder screw when appropriate.

4. Next, the scan tool will instruct to open each bleeder screw an additional 20 seconds, starting again with the right rear corner. This will allow any remaining air to purge out of the system.

4.1.	Before starting bleed procedure, assistant should slowly stroke, apply, and hold the brake pedal.

4.2.	Once the brake pedal is in a held position, press START on the scan tool and open the bleeder screw simultaneously.

4.3.	When the brake pedal reaches the floor, close the bleeder screw. The assistant can now release the brake pedal.

4.4.	The assistant should again stroke, apply, and hold the brake pedal.

4.5.	Open the bleeder screw until the brake pedal reaches the floor. Then close the bleeder screw.

4.6.	Repeat this procedure as many times as possible during the scan tool timed program or until all air is removed.

4.7.	Once scan tool is done cycling the designated brake corner, ensure that the bleeder screw is closed prior to moving on to the next corner.

5. Once all four bleeder screws have been opened and closed the scan tool will display PROCEDURE COMPLETE. The assistant is no longer needed.

Notice: Refer to Fastener Notice in the Preface section.

6. Torque the bleeder screws.

Tighten

•	Tighten the front bleeder screws to 11 N·m (97 lb in).

•	Tighten the rear bleeder screws to 7.5 N·m (66 lb in).

7. Depress the brake pedal to gage pedal height and travel. It may be necessary to repeat steps 1-6 if pedal feel and travel are unacceptable.
8. Remove the scan tool from DLC.
9. Lower the vehicle.
10. Inspect the brake fluid level in the master cylinder reservoir, fill as needed with DOT 3 brake fluid.
11. Road test the vehicle to verify proper brake pedal height and travel.