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Home >> Saturn >> 2003 >> Ion 1 Standard >> Repair and Diagnosis >> Brakes >> Mechanical - Hydraulic >> Disc Brakes & Drum Brakes >> Bleeding Brake System >> Manual Bleeding

Manual Bleeding

  1. Place a clean shop cloth beneath the brake master cylinder to catch brake fluid spills.
  2. With ignition OFF and brakes cool, apply brakes 3-5 times or until brake pedal effort increases significantly, in order to deplete brake booster power reserve.
  3. If you have performed a brake master cylinder bench bleeding, or if you disconnected the brake pipes from master cylinder, or if you have disconnected the brake pipes from the proportioning valve assembly or the brake modulator assembly, you must perform the following steps to bleed air at the ports of the hydraulic component:
    1. Ensure that brake master cylinder reservoir is full to the maximum-fill level. If necessary, add DOT-3 brake fluid from a clean, sealed brake fluid container. If removal of reservoir cap and diaphragm is necessary, clean outside of reservoir on and around the cap prior to removal.
    2. With brake pipes installed securely to master cylinder, proportioning valve assembly, or brake modulator assembly, loosen and separate one of the brake pipes from the port of the component. For the proportioning valve assembly or the brake modulator assembly, perform in the sequence of system flow. Begin with fluid feed pipes from master cylinder.
    3. Allow a small amount of brake fluid to gravity bleed from the open port of the component.
    4. Reconnect brake pipe to component and tighten securely.
    5. Have an assistant slowly depress brake pedal fully and maintain steady pressure on pedal.
    6. Loosen same brake pipe to purge air from the open port of the component.
    7. Tighten brake pipe, then have assistant slowly release brake pedal.
    8. Wait 15 seconds, then repeat step  3 until all air is purged from the same port of the component.
    9. With brake pipe installed securely to the master cylinder, proportioning valve assembly, or brake modulator assembly, loosen and separate the next brake pipe from the component, then repeat step  3, until each of the ports on the component has been bled.
    10. After completing the final component port bleeding procedure, ensure that each of the brake pipe-to-component fittings are properly tightened.
  4. Fill brake master cylinder reservoir with DOT-3 brake fluid from a clean, sealed brake fluid container. Ensure that brake master cylinder reservoir remains at least half-full during this bleeding procedure. Add fluid as needed to maintain the proper level. Clean outside of reservoir on and around the reservoir cap prior to removing the cap and diaphragm.
  5. Install a proper box-end wrench onto the RIGHT REAR wheel hydraulic circuit bleeder valve.
  6. Install a transparent hose over the end of bleeder valve.
  7. Submerge open end of the transparent hose into a transparent container partially filled with clean brake fluid.
  8. Have assistant slowly depress brake pedal fully and maintain steady pressure on pedal.
  9. Loosen bleeder valve to purge air from wheel hydraulic circuit.
  10. Tighten bleeder valve, then have assistant slowly release brake pedal.
  11. Wait 15 seconds, then repeat step  8 until all air is purged from the same wheel hydraulic circuit.
  12. With right rear wheel hydraulic circuit bleeder valve tightened securely, install box-end wrench onto the LEFT FRONT wheel hydraulic circuit bleeder valve.
  13. Install a transparent hose over the end of the bleeder valve, then repeat step  7.
  14. With left front wheel hydraulic circuit bleeder valve tightened securely, install box-end wrench onto the LEFT REAR wheel hydraulic circuit bleeder valve.
  15. Install a transparent hose over the end of the bleeder valve, then repeat step  7.
  16. With left rear wheel hydraulic circuit bleeder valve tightened securely, install box-end wrench onto the RIGHT FRONT wheel hydraulic circuit bleeder valve.
  17. Install a transparent hose over the end of the bleeder valve, then repeat step  7.
  18. After completing the final wheel hydraulic circuit bleeding procedure, ensure that each of the 4 wheel hydraulic circuit bleeder valves are properly tightened.
  19. Fill the brake master cylinder reservoir to the maximum-fill level with clean DOT-3 brake fluid.
  20. Slowly depress and release brake pedal. Observe feel of brake pedal.
  21. If brake pedal feels spongy, repeat the bleeding procedure again. If brake pedal still feels spongy after repeating the bleeding procedure, inspect brake system for external leaks. Pressure bleed hydraulic brake system in order to purge any air that may still be trapped in the system. See PRESSURE BLEEDING .
  22. Turn ignition on, with engine off. Check if brake system warning light remains illuminated.
    23. NOTE: DO NOT allow vehicle to be driven until warning light is diagnosed and repaired.
  23. If brake system warning light remains illuminated, diagnose problem. See TESTING .
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