5.2 - abs braking system [ocr]
TRANSCRIPT
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Saab 9
S RVI MANUAL
5:
S
braking
system
989
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599 Alphabetical section guide
59
ASS-system tester
53 Changing the
hr;alke
1fluid
52
Bleeding
the br ke
s y s ~ m
5
ComponeRI remov.allfittiT} g
5 ABS
control:
d escrJpti O:n of
operation
5 Technioal des ori1ptLon
25
Technical
t
5
Special tools
El
D
t
I
I
i
I
I
i
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Technical data 025-1
ATE
10-14
-30to
+8 0
-22to
+176)
0-1.80 0 - 2610)
140 - 180 2030 -2610)
v
c OF
bar psi)
bar psi)
>
H y d l i a u ~ C IUIl lBft
., . Make
. ,. W or ki ng vol ta ge
11
..
;> Working temperature
Pressures: Brake circuits
- - - - - - - - - - - - - - - - - - - -+ - - _ - - - . : . . . -
- - - . : . .. - _ - - - - - - - - - - - -
Accumulator
Reservoir capacity
litres Iiq qt) 0.8 0.84)
Total capacity
of
brake
system litres Iiq qt)
1.2
1.3)
Brake fluid specification
DOT4
Number of chambers . 3
NO.1 chamber
Static
circuit
NO.2 chamb.er
Dynamic circuit to pump)
NO.3 chamber
Dynamic circuit return from servo)
Filterflow capacity litres/min
I/Iiqqt) 0.5 0.5)
Fluid level indicator
resistance ohm
10
reservoir empty)
ABS-warningswitch resistance ohm 1 reservoir full)
I ...
Type
Ball-valve
0.1-1.0
0.45-14.5)
140 -180 2030 - 2610)
bar psi)
bar psi)
Pressure: Inletside
~ - - - - - - - - - - - - - - - - - + - - - _ : . . . . - - _ - _ : . . . . - - _ - - - - - - - -
Del ivery side
Reliefvalveopening pressure
Power demand
Maximum running time
bar psi)
210 3045)
180 at 160 bar)
2 m in
at
ati me followed
by
10-min pause pump must notbe run
dry
Gas
Nitrogen
Gas pressure at 20C 68F)
bar psi) 80 1160)
Minimum gas pressure
bar psi)
40
580)
Fluid capacity
Iitres I iqqt) 0.25 0.26)
Working pressure range
bar psi)
135
-190 1958- 2755)
Maximum pressure drop
bar psi)
10min 10 145)
Saab900
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025-2
Technical data
Pressure switch:
Breakscircuit
at
bar psi
180
4
2610
58
Makes circu
i ta t
bar psi
140
4
2030
58
Warning-lightswitch:
Breakscircuit
at
bar psi
134
2
1943
29
Makes circuit
at
bar psi
105
2
1523 29
Maximum working pressure
bar psi 180 2610
Power rating
at 12
V W
35
Resistance ohm
5- 7
SoHenoid
v ~ v s
Maximumworking pressure
bar psi
180
40 2610
580
Saab
26
4 19 3
25
20-26 15-19
5-7
36
2.2
34-46
25-34
0.65
0.026
94
0.15-0.70
800-1400
7-18
40
-40to +8 0 -40
to
+176
V
ohm
Va.c.
ohm
W
mm in
Nm Ibfft
Nm
Ibfft
Nm
Ibfft
Powerrati ng
at
12 V
Pressureswitch
Resistance
Flow capacity
at
20C and
100 bar
Accumulator
Hydraulic unit
No.
of
teeth
Wheel sensor - sensor wheel
clearance
Workingvoltage range
Workingtemperatur e range
Resistance
Workingvoltage range
Power rating
Wll eeDselrnsovs
IECU
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ABS-system tester
89965
Pressure sensor included with
S-
system tester
899657 Socket for removal/fitting of pres
sure switch
peci l tools
1 5 1
8996589
Extension lead,
ECU
to ABS-system
tester
8996597
Adaptor hose for connect ing pres
sure sensor
to
hydraulic
unit
Saab
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echnic l description 5 1
General .
Principles
of
operation.
5 1
500-5
Components 5 11
S
brakes Anti-lock Braking System have
been developed to provide opt imum braking,
with no loss
of
direction or stability, underwidely
varying conditions.
The
stopping distance of a
caris influenced by avarietyoffactors, including
weather conditions, road surface, prevail ing
traffic conditions, braking effort applied.
The SS
system provides modern braking sys
tems with a control funct ion that enables the
maximum braking effect to be exploited in crit i
cal situations, regardless ofthe road conditions.
The
system automatically monitors and mod
ulatesthe brake pressurefor eachfront wheel in
dividually and forthe rearwheelstogetherto pre
vent the wheels from locking.
The
shortestpossi
ble stopping distance istherefore achieved with
out any loss
of
steering control.
The
main advantages of the
S
system are as
follows:
No
loss
of
directional stability
on
braking
l
Steering control retained even when brakes
hard on
o
Shortest possible stopping distance
Reduced tyre wear
Saab900
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500 2 Technical description
To
understand how the ASS system provides op-
timum braking without any loss of directional
Direction
oftravel
stability, we need to examine the forces acting
on a wheel during braking.
Braking force Lateral force
1
All t he forces taken up by the tyre are e ither lateral
forces
or
braking forces
.
On
the adjacent chart, the curve I) shows the re-
lationship between braking force expressed as
a coefficient) and tyre sl ip expressed as a per
centage),.
The braking force is equivalent to the coefficient
of
adhesion, i.e. the friction between the tyre
and the road surface. Each application of a brak
ing force gives rise to a certain degree of slip,
, ranging from 0 when the wheel is rolling freely
to
100
when the wheel is locked.
When the brake is
first
applied, the braking force
increases sharply, but the degree of slip only
gradually, up to a certain l imi t. Beyond
that
point,
the
braking force wil l decrease with in
creasing slip.
li< l :::,.....,--,.,.,.,.,.,=== .....ub-;:.. t - . . : : : i ~ I ~ I : : : : : : I : : : I ~ l m l
the inlet valve, reducing the speed of rota
tion ofthe wheel. The used fluid is replaced by
f lu id s up pl ie d f rom t he servo cy li nd er via t he
main valve.
Phases 2 and 3 are repeated until t he brake
pedal is released or sufficientadhesion between
the tyre and road surface is regained.
The ECU which receives power from the system
relay, is a sealed m odule.
No
attempt must
be
made
to
open it.
The functi
on of
the ECU is to process the informa
tion signals) received from the wheel sensors
and to translate it into control signals
to
the sol
enoid valves. The ECU monitors
most of
the elec
trical components in the
BS
system and also its
own electronic circuitry. It also monitorsthe hyd
raulic pressure in the accumulator and the brake
fluid level in the reservoir.
If a fault is deteqed the ECU wil l cut out the
BS
system, and switch on the SS Anti-lock) warn
ing l ight. If
the
fault could affect
the
conven
t ional braking system in t he car, t he s ta nd ar d
brake warning
light
will also be switched on. This
will occur if the level
in
the brake fluid reservoir
drops too low or ifthe accumulator pressure falls
outside the specified range.
Saab900
To ensure smooth braking, the valves open and
close up twelve
ti
mes a second. Inthe event of
a wire breaking or a short-circuit occurring,
the
valves will reve rt
to their
de-energized position,
making conventio nal braking possible without
BS
modulation.
The ECU wil l cut out the ABS system via the sys
Technical
descr iption
5 27
When the ABS system is inoperative, the brake
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tem relay on detecting a break in the c ircu it to
the valve block, the main valve orwheel sensors.
The ignition must be switched
of f
and the
fault
rectified before the ABS warning light can be ex-
. tinguished and the
ABS system reqctivated. Even
if the faul t has been recti fied, the ABS warning
light
will remain on
if
the ignit ion has
not
been
switched Off.
The ABS system wil l also be inoperative
if
the
level in the fluid reservoir
falls
too low orthe hyd
raulic pressure drops below
105
bar
1523
psi).
In either
case, both the
ABS
warning
light
and the
brake warning light will come on.
Weak signals f rom the wheel sensors wil l a lso
cause operation
of
the ABS system
to be
sus
pended and the ABS warning light
to
come on. In
such cases, when there is no system fault as
such, assoon as the problemhas been
dealt
with
e.g. topping up the f lu id or restoring the hyd
raulic pressure) the system wil l become opera
tive again and the
ABS
warning light will be extin
guished.
system wil l funct ion l ike a convent ional brake
system.
The signals from the wheel sensors are proces
sed
by
the
ECU
which computes;a ir.eference
speed for the vehicle. The indiMidualsignals are
then compared with this reference
Qpeed lf
any
of
the
signals depart from th is referenc:e valve,
the modulating procedure will
be
activated., as
follows:
Phase
Lock-up tendency detected.
System prevents increase in brake pressure.
Phase
Initiation
of ABS
modulation.
Brake pressure reduc-e:d held constan t or in
creased, depending on increase or decrease in
wheel rpm.
Phase
Tendency
for
wheel to lock gone.
Brake pressure increased depending on road
adhesion checked in phase 2.
Saab
500-28 Technical description
l e ~ y ~ l l I s e l l l a H l i l e ~
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The relays and fuses
f or t he
ABS system are
housed in a special fuse panel fitted alongside
the ECU.
The fuse panel contains the system relay, with a
fuse
for the ECU,
a relay and fuse for
the
pump
motor
and an addit ional fuse for
the ECU.
el y
n
fuse p nel
1 Relay, pump motor
2 Relay,
ECU
3 Fuse, ECU
lOA,
ASS
4 Fuse,
ECU
30A,
ASS
5 Fuse, pump motor 30A, Pump
Bli ake WamU[Bg all ld AS S wamnng IDghts
There are three warning
lights
for
the
brake sys-
]
em:
ANT
Q
Handbrake warning light 1
lOCK
G
ABS Anti-lock warning
light
2
o Brake warning
light
3
Or
The handbrake warning is
not
affected by
the
ABSsystem.
PARK
ANTI
R KE
R KE
lOCK
f lUU)
M
3
L
Saab900
Technical description 5 29
IBHrake wialmulI1lg ~ u g l h ~ 081l:
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ANTU
LOCI {
SaabSOO
If both
of
these l ights are on, this indicates that
the level in
the
f lu id reservoir has dropped
further or the pressure in the accumulator has
dropped below 1 5 bar 1523 psi .
The
ABS system will be inoperative
bu t
reduced
braking
effect
wil l remain i.e. g reater pedal
pressu
re
requ ired .
Ifthe
lights have come
on
because of
insufficient
fluid in the reservoir, leakage in one of the cir
cui ts is ind icated . The car mus t not be driven
further until fauit has been found and
rectified.
If the Iights have come on because of a pressure
drop in the system, neither the power assistance
nor the brake pressure to the rearwheels wil l be
in
proportion to pedal pressure. At worst,
if
no
hydraul ic pressure remains, there wil l be
no
power assistance and no rear-wheel braking. The
front-wheel brakes will stil l operate normally but
without power assistance.
lBli ake wamulmg almd AIBS warrrrnolmg ~ u g l h t
bott
on:
The brake warning light alone will come on if the
level
of fluid
in the reservoir drops below the MIN
mark.
The
brakes and ABS systemwill continueto oper
ate normally.
AlaS Wll i II1lUlmg ~ n g l h t
Olm:
The ABS
Anti-lock warning light alone will come
on if the ECU detects a fault in the ABS system.
Conventional braking power will be available but
the ABS system will be inoperative.
;
h e e ~ SelllSOIrS
5 3
Technical description
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.
; ; ; ; ~ t { ; ~ { r
=
The wheel sensorsoperate on the generator pri n
ciple, i .e. a current is induced in a conductor by
distortion
of
the magnetic field surrounding it.
Distortion
of
the magnetic f ield around the sen
sor is caused by the toothed sensor wheel as
it
passes
the
sensor body: each
time
a tooth pas
ses the sensor the magnetic f ield is reinforced.
Each
time
a gap between the teeth passes the
sensor,
the
magnetic field isweakened. Put sim
ply,
this
means
that
positive + current is gener
ated by each tooth and negative - current by
each gap between the teeth.
Thus, alternating current is generated, the fre
quency and amplitude
of
which (
the
number
of
cycles per second and hal f the peak-to-peak
value, respectively) will vary with
the
speed at
which
the
sensor wheel is turning. From
this
sig
nal, the
ECU
can deduce the speed
of
rotation
of
the wheel.
nsorwh l
F 6 O R l t ~ w h e e l
sensor and sensorwheel
Each sensor has a toothed sensor wheel, which
is press-f it ted onto the constant velocity joint.
The sensorwheel cannot
be
removed.
The sensor is mounted vertically on
the
steering
swivel member, i .e. orientated radially
to
the
sensor wheel. The gap between the sensor and
the sensorwheel can beadjusted by means of an
adjusting
s l e e v ~
and setscrew.
The sensor leads can be disconnected
by
means
of
a connector in the engine compartment.
Because
the
sensor is orientated axially relative
to the sensor wheel, the design
of
the rear sen
sor wheels is different to
that of
the
front
ones.
,The sensor wheel is press-f it ted onto
the
rear
wheel hub and cannot be removed.
The sensor leads can be disconnected
by
means
of
connector underneath the rear seat.
Saab900
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5
1
1
S
c
o
n
tr
ol
de
s
cr
ip
ti
o
n
o
f o
p
e
r
ti
o
n
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T
he
b
ra
ke
s
ys
tem
ca
n
be
in
o
ne
o
f th
re
e
co
nd
i
ti o
ns
:
1
Br
ak
es
o
ff
2
B
ra
ke
s
ap
pl i
ed
w
it h
o
u t
S
mo
d
ul a
ti o
n
3
B
ra
ke
s a
pp
lie
d
w
ith
S m
od
u
la t
io n
Hy
dr
au
lic
p
re
ssu
re
is
p
re
se
nt
be
tw
ee
n
th
e a
cc
u
m
u
la t
or
an
d
th
e c
o
nt r
o l
va
lv
e,
ke
ep
in
g
th e
fe
e
d
p
as
sa
ge
b
et
we
en
t
he
ac
cu
m
ul
a to
r
an
d s
er
vo
cy
-
l
in d
e
r c
los
ed
,
an
d
th
e
re t
ur
n
pa
ss
ag
e
be
tw
ee
n
th
e s
erv
o
cy
lin
de
r a
nd
f
lu i
re s
er
vo
ir
op
en
.
Th
e
se
rv
o
cy
lin
de
r,
m
a
st e
r
cy
lin
de
r
an
d
ot
he
r
h
yd
ra
u l
ic
co
mp
o
ne
nt
s a
re
a
ll
ch
arg
ed
w
it
h f
lu
id
t
atm
o
sp
he
ric
p
re
ss
ur e
.
T
he
i
nle
t a
nd
o
ut l
e t
va
lv
es
in
th
e
val
ve
b
lo c
k
an
d
th
e m
a
in
va
lve
a
re
a
ll i
n
th
e r
es
t
de
-en
e
rg i
ze
d
po
si t
io
n.
Saa
b
control description of oper tion 5 1 2
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i
Accumulator pressure
Atmospheric pressure
r kes
2 Accumulator
3 Pump delivery pipeconnection
4 Control valve
5 Lever mechanism
6 Actuating plunger
7 Servo plunger
8 Rear brake
circuit
9 Front brake circuits
1
Inlet valve in valve block)
11 Outlet valve in valve block)
12
Brake caliper
Saab9
5 1 3
control description of oper tion
IBrralkes a j p I P ~ e d woi holUlt ArBS m o d ~ a t i o n
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When t brake pedal is applied and there is
no
tendency for any wheel to lock, the control valve
admits hydraulic pressure from the accumulator
proportional
to
the pedal pressure.
The pressure
in
the servo cylinder acts
on
the
servo plunger and reinforces the braking force
transmitted to the rearwheels. The servo plunger
acts
on
the tandem plunger, which closes the
central valves, causing pressure to rise
in
the
front-wheel circuits. Hydraulic pressure to the
wheel cylinders is transmitted through the valve
block, in which the inlet and outlet valves are in
the rest de-energized position.
Saab
control description of oper tion 5 1 4
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=:
Accumulator pressure
Mastercylinder pressure servo pressure
Atmospheric pressure
r kes pplie without S modul tion
2 Accumulator
3 Pump delivery pipeconnection
4 Control valve
5 Lever mechanism
6 Actuating plunger
7 Servo plunger
8 Rear brake circuit
9 Front brake circuits
10 Inletvalve in valve block
11 Outletvalve in valve block
12 Brake caliper
Saab
501 5
SS
control: description of operation
[Bll akes
a l l ~ e d
wfittlh
SSmodulation
SSmodulation is initiated when the system de
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tects a tendency for a wheel
to
lock.
s
soon as
the ECU detects from the inpu t s igna ls a ten
dency
for
a wheel to lock,
it
closes the
inlet
valve
for the c ircu it in quest ion. At the same
time
as
the main valve opens, the brake pressure is re
duced as the
outlet
valve for the circuit opens.
When SSmodulat ion is ini tiated, all braking is
effected by accumulator pressure provided via
the control valve inthe servo cylinder. Thus, both
front-wheel circuits will
be
isolated from sta
tic
pressure present in f ront
the
tandem
plunger seals. The circuits are insteadSUbject to
dynamic pressure, caused by t he brake f lu id
being fo rced past the seals to t he chamber
beyond, and thence
to
the valve block in which
the pressure modulation takes place. The
dynamic pressure also acts on the positioning
sleeve, providing a nonpulsat ing reserve
of
pedal travel.
The pressure in the respective circuits is depen
dent
on the
retardation inwheel speed sensed
by
the sensors. The ECU controls the inlet and out
let valves so thatmaximum braking force coeffi
cient of adhesion is maintained between the
wheel and road sur face occurr ing at approx.
20
slip .
ASS-modulated braking will continue until:
the car has brought
to
a standstill
o the force applied by the driver
t o t he
brake
pedal has been reduced to the level
at
which
there is
no
danger
of
the wheels locking de
termined
by
the relationship between braking
force and the coefficient
of
adhesion .
Note
that
the pressure in the circuits can never
exceed
the
pressure applied to the brake pedal
by the driver.
The brake fluid returned to the reservoir via the
outlet valves is replaced
by
f luid from
the
ac
cumulator. The capacity
of
the accumulator is
sufficient
to
ensure
that
the required quantity
of
pressurized brake fluid will always be available
during ASS-modulated braking.
Saab900
SS control: description of operation
501-6
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t ~ ~ : t ~
L
Accumulator pressure
Master cylinder pressure servo pressure
Atmospheric pressure
rakes appliedwith Smodulation
2 Accumulator
3
ump
delivery pipeconnection
4 Control valve
5 Lever mechanism
6 Actuating plunger
7 Servo plunger
8 Rear brake circuit
9 Front brake circuits
10 Inlet
valve
in
valve
block
11 Outlet valve in valve block
12 Brake caliper
Saab900
..
J
D
J
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omponent removal fitting
51 1
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51 2
51 23
51 26
51 27
Pump and motor
unit
Valve block
U
Wheel sensors
51
51
51 12
51 13
51 15
o r mov
Brake fluid reservoir
Hydraulic unit
~ c c u m u l t o r
P ressure switch
Pump delivery pipe
Saab9
1 Remove the
ir
intake
2 Remove the retaining
bolt
forthe coolant ex-
pansion tank and move the tank out of
the
way
51 2
omponent removal fitting
3 Siphon of f the f luid from the reservoir. Note
that itwil l notbe possibleto
emptythe
reser-
voir completely.
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4 Unplug the electrical connector
for
the f luid
level indicator
onthe
reservoir.
Manuals only: Disconnect the hose for the
clutch cylinder and plug the end.
Take care not
to
lose any fluid from the hose.
.
ffluid is lost air may get into the clutch hyd-
raulics
6 Undo the reservoir retaining screw.
~ ~ ~ f . f ; ~ ~ ~ ~ l f t ~ ~ t ~ ~ : ~ ~ ~ ~ i f ~ ~ : : : ; 2 ' ~ ~ ~ ' ~ J o 2 ~ : ' S ( ; ~ ~ : : : , ' . ~ : . '
.
....
;.
.
Saab
omponent removal fitting
51 3
Lift the reservoir
of f
the hydraulic unit y
withdrawing
it
from the rubber bushes
Take care not to lose the spacer
nd
ring
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Saab9
8 Disconnectthe pump feed hose from the re-
servoir
on
the rear connection
9 Remove the rubber bushes from the hyd
raulic unit
51 4
Component remova l/ fi tt ing
1
f
it
1
F
it t
wo
n
ew
r
ub
be
r
bu
sh
es
in
t
he
h
yd
ra
ul i
c
un
it .
-
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2
Re
co
nn
ec
t t
he
p
um
p
fe
ed
h
os
e t
o_
the
r
es
er
v
oi
r.
,
f
.
:
Sl
ide
t
he
sp
a
ce
r a
nd
i O
rin
g o
n
to
the
r
es
er
vo
ir
re
ar
GU
n
ne
cti
on
; I
hs
tal
l th
e
re
se
rv
oi
r b
y
pus hi ng
th-e
con ne ct io ns
i
nto
t
he
rub
b
er
b
us
he
s i
n th
e-
h
yd
ta
u li
c u
n
it.
4 Ti
gh
te n
t
he
re
se
rv
oi
r re
ta
in
in g
s
cr
ew
.
5
Ma
n
ua
ls
on
ly
: R
e
co
nn
ec
t
th
e
clu
tc
h
fe
ed
ho
s
e to
th
e r
es
er
vo
ir.
M
ak
e
su
re
t
ha
t fl
ui
d
h
as
n
ot
be
en
lo
s
t fr
om
t
he
h
os
e.
Pl
ug
;t h
e
el
ec
tr i
ca
l c
on
ne
ct
or
o
nto
th
e
fl
u id
le
ve
l
ihd
ic
ato
r.
7
Mo
ve
th
e
c
oo
la
nt
ex
pa
ns
io
n
tan
k
ba
ck
in
to
pl ace and t igh te n the bol t.
8
R
ef
it t
he
air
in
ta
ke
.
9
F
iW
th
er
es
er
vo
ir w
it
h
DO
T
4 b
ra
ke
fl
u id
.
1
B
le
e
d
th
e b
ra
ke
s
ys
tem
.
F
or d
et
ai
ls
re
fer t
o
s
ec
ti o
n
5
2
1
1
S
w
itc
h
on
th
e
ign
it
ion
a
nd
w
at
ch
to
se
e t
ha
t
the
b
ra
ke
a
nd
A
SS
(A
n
ti-l
oc
k)
w
arn
in
g
lig
h ts
g
o
of
f.
1
2
Te
st
dr
ive
t
he
c
ar
an
d
ve
rif
y t
ha
t
the
b
ra
ke
sy stem is working prop er ly .
S
aa
b9
Component removal/fitting
51 5
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10ll emmfe
1 Remove
the
centre console
2 Remove t he padded t ri m pane l f ro m be lo w
the
dash
Saab9
51 6
omponent removal fitting
3 Remove the heater duct
i
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4 Remove the acoustic insulation from behind
th pedal assembly
5 Disconnect th defroster hose from tt \e
heater box
6 Remove t he p in r et ai ni ng c li p and w it hd ra w
th pin from th hydraulic
unit
pushrod
7 Remove t he
ir
intake
Saab
I
omponent removal fitting
51 7
Remove the retaining olt
forth
coolant ex-
pansion tank and move the tank out
of
the
w y
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Saab
9 Unplug all e lect ri ca l connectors from the
hydraulic unit:
o
pressure switch 1
main valve 2
o fluid level indicator 3
pump motor 4
51 8
Component removal/fitting
1 Unbol t the bracket between the hydraul ic
unit
and
front
assembly. Disconnect the
earth lead and unplug the connector
for the
sensor lead. Move
the
bracket and electrical
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leads out of
the
way.
11 Siphon off
the fluid
from the reservoir. Note
that it will
not
be
possibleto
empty the reser-
voir completely.
12 Manuals only: Unplugthe hose
for
the clutch
cylinder and plug
the
end.
Take care notto lose anyfluid from the hose.
Iffluid is lost
air
may get into
the
clutch hyd-
raulics.
13
Label the brake pipes and the large bore re-
turn pipe.
14 Disconnect the brake pipes and large bore
return
pipe together to avoid putt ing ten-
sion on the pipes.
Plugthe ends ofthe pipes and
the
openings
in
the
hydraulic
unit
and valve block.
15 Undo the four securing nuts forthe hydraulic
unit the
bulkhead behind the pedal as-
sembly.
16
Lift out
the hydraulic unit.
Saab9
Component removal/fitting 510-9
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Noie
On f it ti ng
t he hydraulic uni t, i t i s easy for the
stop-I ight switch and cruise-control switch i f
: any
to
be pushed inadvertently. If so, use a
: pai r
of
pliers to reset them.
,
.
1 : _ .
,
1 Offer up the hydraulic
unit
and ensure
that
t he pushrod is co rrect ly a li gned with the
pedal assembly.
2 Reconnect the pushrod,
fitting the
pin and
pin retaining clip.
3 Tighten the hydraul ic
unit
retaining nuts o
the bulkhead behind the pedal assembly.
Tightening torque:
26
4 Nm
19
3
Ibf
f
4 Connect the brake pipes and large-bore re
turn pipe.
Saab900
51 1
omponent removal fitting
Manuals only: Reconnect
th
clutch feed
hose to the reservoir Make sure th t fluid
has not been lost from the hose
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6 Plug the sensor lead connector and
fi t
the
bracket between the hydraulic unitand front
assembly Remember to secure the earth
lead the top bolt
Saab 9
Component removal/fitting
51 11
7 Reconnect all the electrical leads:
pressure switch 1)
main valve 2)
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Saab9
fluid level indicator
3
pump motor
4
8
Move the coolant expansion tank back into
place and tighten the bolt.
9
Refit the
air
intake.
,
1
Fill the reservoir with
DOT
4 brake fluid.
11
Switch
on
the ign it ion and check
tha t the
pump is working.
12
Bleed the brake system.
For detai ls refer to section 520.
13
Inspectthe brake system for leaks and check
that the brake and ABS Anti-lock) warning
lights go
off
14
Reconnect the
LH
defroster hose.
15
Fit the acoustic insulat ion behind the pedal
assembly.
16
Refit the heater duct.
17
Refit the padded trim panel underthe dash.
18
Refit the centre console.
19
Test drive the car and verify
that
the brakes
and clutch are working properly.
510-12
Component removal/fitting
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Yo
remove
1 Removethe accumulator 8-mm Allen key .
Yo tnt
1 Fit a new
0
ring
on
the accumulator.
2 Fit the accumulator.
Tighfl:eningtorql,le: 3446 Nm
25
-
341bf
ft
3 Switch
o n ~ h e
ignition and watch
to
see
that
the
r k ~ n d
S
Anti-lock warning lights
go off.
4 Test drive the car and verify
tha t the
brake
system is working properly.
r
Saab900
Component removal/fitting
51 13
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Saab
9
: ; : ~ ~ ~ : d :
:--
3 Fit special tool
8996571
and unscrew the
switch
1 Remove the rubber damper f rom the pump
delivery pipe
2 Unplug the e lec tr ical connecto r from the
pressure switch
To emove
H i n ~
Ifthe
switch is
difficultto
und insert a suitable
brace between the pump body and the hydraulic
unit
b
lO
4
Component removal/f it t in g
1
Fi t
a
ne
w
0
r
ing
a
nd
s
cr
ew
in
th
e
p
res
su
re
sw
itc
h.
T
ig
ht
en
in
g t
or q
u
e:
20
-
26
N
m
1
5
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-
1
9
I
bf
ft
2
u
g t
he
co
n
ne
ct o
r
on
to th
e
p
re
ss
ur
e s
w
itc
h .
.
3
F
it t
he
ru
bb
er
da
m
pe
r o
n
to
th e
p
um
p
de
l i
ve
ry
pipe.
4
S
wi t
ch o
n
t
he
ig
n
it io
n
an
d
wa
tc
h t
o
se
e
th
a
t
t
he
b
rak
e
an
d
A
nt i
-lo
ck
w
a
rn
ing
li
gh
ts
go
of
f.
5
I
ns
pe
ct
th e
b
ra
ke
s
ys
tem
f
or
6
T
es
t d
riv
e
th
e c
a
r a
nd
v
er
ify th
at
th
e
br
ak
e
s
ys
tem
i
s w
o
rk
ing
p
ro
pe
rly
.
S
aa
b9
00
Component removal/fitting
510 15
.
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Saab900
2 Remove the retainingbolt for the coolant ex-
pansion tank and move the tank out
of
the
way
3 SiphQ:t1offthe flufd from the reservoir Note
that itwil l
not bep0ssibl:e
t o
emptythe reser-
voi r completely
To Il emove
1 Remove the air intake
51 16
Component removal fitting
4 Unplug the electrical connector for the fluid
level
indicator on the reservoir
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Saab PO
5 Manuals only: Disconnect the hose for the
clutch cylinder and plug the end
Take care notto lose anyfluid from the hose
Iffluid
is lost air may
get
into the clutch hyd-
raulics
6 Undo the reservoir retaining screw
T Lift
the
reservoir
off
the hydraulic
unit y
withdrawing
it
from the rubber bushes
Take care not to losethe spacer and ring
on the rear connection
Plug the holes in the rubber bushes n the
hydraulic unit
ompon nt
removal fitting
51 17
8 Disconnect the rear brake pipe
on
the hyd-
raulic unit to gain betteraccess tothe pump
delivery pipe coupling
Plug the end
ofthe
brake pipe
n
the open-
ing
in
the hydraulic unit
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Saab
9 Remove the pump delivery pipe
Plug the two openings for the pipe
in
the
unit
51 18 omponent removalfitting
it
F
it
t
h p
um
p
d
eli
ve
ry
pip
e
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2
R
ec
on
ne
c
t
th
re
ar
br
ak
e p
ip
e
Saa
b
Component removal/fitting
510 19
,
1
3 Slide the spacer and 0 ring onto the reser-
tj voir rear connection. Install the reservoir
by
pushing the connect ions in to the rubber
bushes in the hydraulic unit.
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4 Tighten the reservoir retaining screw.
5 Manuals only: Reconnect the c lutch feed
hose
to
the reservoir. Make sure
that
fluid
has
not
been lostfrom the hose.
6 Plug the elect rica l connector onto the f lu id
level indicator.
7 Move the coolant expansion tank back into
place and tighten
th e
bolt.
8 Ref it the air intake.
9 Fi ll the reservoir with DOT brake fluid.
10
Bleed the brake system.
For details refer to section 520.
11
Switch
on
the ignition and watch
to
see
that
the brake and
BS
Anti-lock warning lights
go off.
12
Test drive the car and ver ify
that
the brake
system is working properly.
F
,
i
r
;
r ;
i
Saab900
51 2
Component removal fitting
The pump and motor
unit
cannotbe removed with
the
hydraulic unit
the car
-
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Unt
It
i s a good idea
to
remove the a ccumulator be-
fore the hydraulic
unit
is removed from the car
Plugthe opening in the pump body
1 Disconnectthe pump delivery pipe from the
pump unit
Plug the open end
of
the pipe
2 Prise back the catch and unplugthe elect ri -
cal connector
3 Disconnect the
inlet
hose from the pump
unit
Saab9
Component removal fitting
51 21
Undo the securing screw at the front of the
pump unit
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Saab
. . ( : \ ; : ~ ~ . ~ j
Note the order for reassembl ing the dam-
pers washers and spacer
Hint
If
the switch is
difficultto
und
inserta suit-
able brace between the pump body and the
hydraulic unit
5 Disengage the pump and motor
unit
from its
rear mounting
6 Remove the pressure switch
s
special tool 899657
51
0
-
2
2
C
o
m
p
on
e
n
t remova l/f it t ing
T
o
fi
t
1
F
it
a
ne
w
0
ri
ng
a
nd
sc
re
w
in
th
e
pr
es
su
re
sw
it
ch
.
T i
gh
te
ni n
g
to
rq
ue
: .
2
0
-
2
6 \
\ m
15
- 1
9
Ib
f f
t
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2
R
ec
on
ne
ct
th
e
in
le
t ho
se
to
t
he
p
um
p
un
it.
3
En
g
ag
e t
he
re
ar
m
ou
nt
in g
o
n
the
p
um
p
un
it .
4
As
se
m
ble
t
he
da
m
pe
rs
, w
as
he
rs
a
nd
sp
a
ce
r
a
s s
ho
w
n
an
d
fit
th
e s
e
cu
rin
g
bo
lt .
5
P
lug
the
e
le
ctr
ic a
l
co
nn
ec
to
r.
6
R
ec
on
ne
ct
th
e
p
um
p
de
liv
e
ry
pi
pe
to
th
e
pu
m
p
un
it .
Refi t th e hy dr au lic uni t in th e ca
r.
Fi
t th
e
ac
cu
m
ul
a to
r.
T ig
h
ten
in
g
tor
qu
e:
34
- 4
6
m
2
5 -
34
Ib
f
fa
Sa
ab
omponent removal fitting
51 23
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remove
Remove the air intake
2
mov
the retaining
boltforthe
coolant
x-
pansion tank and move the tank out
of
the
way
3 Siphon
of f
the
fluid
from
the
reservoir Note
that itwill notbe possible to empty the reser-
voir completely
4 Unplugthe electrical connector
on
the valve
block
Saab9
5 Disconnect the brake pipes from the under-
side of the valve block:
1 front left nearest wing
2 rear middle
3 front right nearest engine
51 24
Component removal/fitting
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Saab
nt
To
stop brake fluid escaping, raise the ends
ofthe
pipes and
lightlytightell
downtIle con-
nections to the hydraulic unit.
Plug the ends of the brake pipes and return
pipe, and the openings in the valve block.
Hint
Place a rag under the valve block connec-
tions
to prevent brake fluid gett ing onto the
paintwork.
Undo the nut on the cover underneath the
pipes.
Slacken off the connections at the hydraulic
unitto
avoid stressing the pipes.
7 Withdraw the brake pipes and return pipe
from the valve block.
6 Disconnect the brake pipes and the large-
bore return pipe from the valve block.
8 Snipthrough thetie securingthe wiring loom
to the valve block.
9 Remove the three nuts and lift of f the valve
block.
I
Component removal/fitting
510 25
lome
1 Lift the valve block into posit ion and tighten
the three nuts.
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2 Reconnect the brake pipes to the underside
of
the
valve block:
o 1) front left nearest wing)
o 2) rear middle)
o 3) front right nearest engine)
Secure the wiring loom to the valve block by
means of a cable tie.
4
Slacken off the connections
atthe
hydrau Iic
unit.
Connect the brake pipes and return pipe to
the valve block. Tighten the
fittings
:>i
Fitthe cover forthe underside of
the
pipes to
,
the
wing.
5
Plug on the connectorfor the valve block.
6
Move the coolant expansion
tank
back into
place and tighten the bolt.
7
Refit the air intake.
8
Fill
the
reservoir with DOT 4 brake fluid.
9
Bleed the brake system.
For details refer to section
520
10
Inspect the brake system for leaks. Switch
on the ignition and check that the brake and
S Anti-lock) warning lights go off.
11
Test drive
the
car and verify that the brake
system is working properly.
Saab900
L
510:-26 Component removal/fitting
Note
The
U
must
not
be exposed
to
hi gh tempera
tures. Always remove
it
from the carbefore start
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ing any arc welding stove drying etc.
Il emove
1 Unscrew the
U
from the
LH
wing insidethe
engine bay.
2 Lift up the U module and unplug the con
nector.
1 Plugthe connector onto the module.
2 Screw th e
U
module into place.
Saab
lTemove
flr n ft
Q
wll ee Sell1lS0ffS
Component removal/fitting
51 27
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Saab
9
1 Unplug the sensor lead connector one fo r
each wheel inside the,.engine bay by push-
ing the halves together and twisting
bayonet fitting .
2 Raise the
front of the car and remove the
road wheel.
3 Withdrawthesensorlead fromthe
gu
ide and
pull it through the rubber grommet in the
wheel arch.
510 28
Component remova
I fitting
4 Undo the screw and remove the sensor.
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Saab9QO
Note the plast ic sleeve that is
fitted
to pre-
vent corrosion between the steering swivel
member and the sensor.
rRea mwheei senSO[fS
1 Unplug the sensor lead connector one for
each rear wheel located under the rear seat
by pushing the halves together and
twisting
bayonet fitting .
2 Raise the car and remove the road wheel.
3 Pull the sensor lead through the rubber
grommet in the floor.
omponent removal fitting
51 29
Undo the clip securing the handbrake cable
to
th suspension arm
Note the position o the distance piece
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Saab
5 Release the sensor lead from the guide
th back
o
the suspension arm
6 Undothe screw and remove the sensor
510 30
Component removal/fitting
The following items
must
be carried out before
the
new wheel sensor
is f i tted.
Note
o secure the sensor inthe vice grip the adjust
ing sleeve
in
the jaws. Never clamp the sensor
body
itself
as
this
can
distort
it.
0
:
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Undo the setscrew and transfer the adjusting
. sleeve
to
t he new sensor. Check
that
the
sleeve slides freely: if necessary polish the
surface with a piece
offine
emery cloth. Clean
the surface thoroughly and lubricate l ight ly
before
fitting
the sleeve.
G
se
a wire brush
to
remove all tracesofthe old
fibre spacer from
the
end
ofthe
sensor. Clean
the
surface with a rag
i f
required moistened
with a
little
petrol/gasoline .
o Remove any traces
of f ibre or dir t
from inside
the
sensor housing. Spin the sensor wheel
slowly and remove any
fibre
remains or d ir t
from between the teeth. At
the
same time in
spect
for
signs of damage.
Glue a new f ib re spacer onto the end of the
sensor.
Spacer thickness:
0.65
mm
Note
Once
the
sensor with
the
new fibre spacer has
been pushed out towards the sensor wheel the
road-wheel hub must
not
be rotated before the
sensor has been secured in
its
correct position.
If
the hub is rotated premature ly the sensor
wheel will
tearthe
spacer causing the sensorto
be
set
incorrectly. Offset the adjusting sleeve
half-a-turn to bring the setscrew
to
a new posi
tion.
Saab900
omponent removal fitting
51 31
fvoll1ft
g
wheeD
se11lS0B S
Fit the sensor tightening the retaini[lg
screw.
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;
.
Saab
2 Press the sensor body gent ly aga inst the
sensor wheel and tighten the setscrew.
3 Insertthe sensor lead through the grommet
in the wheel arch and secure it
in the guide.
4 Reconnect the sensor lead connector inside
the engine compartment.
5 Fit the road wheel.
After fitting ensure
th t
the sensor lead
cannot chafe againstany
of
the components
when the wheel is at ful l lock.
I
51 32
omponent removal fitting
l e a l l i m w ~ e e ~
seIrilSO S
1 Fit the sensor t ig ht eni ng th e retaining
screw
;
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Saab
2 Press the sensor body gently aga inst the
sensorwheel and tighten the setscrew
3 Fit t he
cl ip for the handbrake cable onto the
suspension arm
Note the position
o
the distance piece
4 Insert the sensor lead through the grommet
in the f loor and secure t to the suspension
arm
5 Reconnect the sensor lead connector under
the rear seat
6 Fi t the road wheel
Bleeding the brake
syst
52 1
~ o t
L;
The front wheel brakecircuits mustbe bled first.
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Saab
3 Have a helpe r depress the brake pedal as
you
undo the nipple.
With the pedal down to the floor tighten the
nipple and then release the pedal.
Repeat this operation until no ir bubbles
are visible
in
the hose.
Repeat s teps 2 and 3 to bleed the
circuit
for the
front wheel.
f required a bleeder unit can be used for
the
.
front brake circuits.
1 Top up as necessary with
DOT
4 brake fluid.
2 Connect a length of transparent hose to the
bleed nipple on the
R
front brake caliper.
Place
the
other end of the hose in a suitable
receptacle.
52 2
Bleeding
the
brake system
Note
The front wheel brake circuits mustbe bled first.
1 Top upthe reservoir as required with
OT
4
rl
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brake fluid.
2 Connect a length of t ransparent hose to the
bleed nipple
on
one
of
the rear brake cal ip-
ers. Place the otherend of the hose in a suit-
able receptacle.
3 Have a helperswi tch on the ignit ion and de-
press the brake pedal.
4 Undo th e brake nipple and draw
of f
brake
fluid
until no bubblesarevisible inthe tube.
To bleed the remainder
of
the c ircu it to the
other wheel repeat steps 2 3 and 4.
5 Top up the brakef lu id
to
bring the level up to
the
M X mark on the side
of
the reservoir.
Saab9
Changing the brake fluid
530-1
All brake fluid deteriorates
after
a
time
through
i i oxidation and absorption of water. This lowers
t: ~ t h e
boiling pointof the fluid, which maytherefore
> . vaporize during prolonged hard braking. The re-
r
f
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; C S H l J I ~ i O i 1
To
avoid possible brake failure, all old brake fluid
must be drained from the system. The fluid
capacity
of the
brake system is approx.
1.2
litre
i
1.3
l iq qt).
sult
can be sudden brake failure. It is therefore
essential that the brake fluid is changed regu-
larly at the specified intervals (see the Mainte-
nance Programme in Section 1:2 of the Service
Manual).
If requi red, a bleeder uni t can be used for the
front brake circuits.
1 Siphon of f the fluid from the reservoir. Note
that itwill be notbe possibleto emptythe re-
servoir completely.
2
Top
up with
OT
4 brake fluid.
3 Connecta length of transparent hose to the
bleed nipple on the
RH
front brake caliper.
Place the other end of the hose in a measur-
ing cylinder or other graduated receptacle.
4 Have a helpe r depress the brake pedal as
you
undo the nipple.
With the pedal down to the floor, t ighten the
nipple and then release the pedal.
Repeat the procedure until approx. 0.5litres
(0.5 l iq qt) has been drained off.
To drain the circuit forthe LH front wheel: repeat
s teps 3 4, except this
time
drain of f approx.
0.1
litre
0.1Iiqqt)
offluid.,
Saab900
530 2
Changing the brake fluid
Connect a length
of
transparent hose to the
bleed nipple
on
one
of
the rear brake calip-
ers Place the other end
ofthe
hose in a suit-
able receptacle
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6 Have a helperswi tch on the ignition and de-
pressothre brake pedal
7 Openthe bleed nipple until approx
0.1
litre
O l l i q q t ~ o f fluid has been drained off
..
Repeat steps 5 6 and 7 to drain the
remainderof
the
circuit to the other wheel
8 Fill up wi th brakef lu id
to
bringthe level up to
the X mark on the side
ofthe
reservoir
Saab900
r
ASS-system tester 590- 1
.590 15
5 .9 0- 16
5 .9 0- 18
:5 90 22
590 26
Selecting the ABS-system version
Test mode
Valve
test
mode
Monitor mode .
Error codes: ,
. 590 1
, 590 2
590
8
590 11
590 13
Technical d ata , . , . . .
;Technical description . . .
Quick checks _.
; Connecting the
tester
to the car
..Connecting the pressure sensor
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The casing of t he t es te r u ni t
is
made
of impact
and o il -r es is ta nt p la st ic and in corpo rate s a
hinged cover over
the
display and control panel.
r n S ~ a y .
Specially designed
LCD
display having
56
seg
ments.
590 27
Fault-diagnosisrouti,nes
590 14
Checking
the accumulator
., gas pressure . . . . .
Special oil-resistant design incorporating three
membrane switches.
Mncmpll Ocessoll
Eight-bit sin gle-chip microprocessor with
analogue/digital converter and 4 K internal stor
age.
lP oweil
COB11SMmlPtnOIl11
Approx. 17 0
m A in
ready mode.
Connection between the
ECU
and the car s wiring
loom is made using a two-way male/female)
35
.
f.
pin connector. :
The power supply
for
t he t es te r is t ak en d ir ec t
f ro m t he b at te ry vi a a lead f it te d w it h c ro co di le
clips.
A pressure sensor can
be
connected to the
ABS
accumulator
for
measuring hydraulic pressure.
Saab
900
59 2
SS system tester
t G e 6 i l e R a ~
The SaabASS-system tester has been developed
for efficient servicing and fault-diagnosis work
on the Saab
braking system.
The equipment comprises the following compo
.
. ~ ; ~ - . :
The
tester
can be usedfbdhr.ee
different
sets
of
tests : ~ . : : . .
a Automatic testing
of
eacti-Wheel sensor and
lead, and
of
the hydraulic pressure in the sys-
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nents:
Tester
o
Test lead with a two-way 35-pin connector
Power supply lead
Pressure sensor with connecting lead
tem Test Mode .
b Manual valve testing ValveTest Mode
c Manual
tes ting of
each wheel sensor and
lead, and
of
the hydraulic pressure in the
brake system Monitor Mode
BS system t st
1 Testerunit
2 Test lead with two-way 5 pin connector
3 Power supply lead
4 Pressure sensorwith connecting lead
5 Port for power supply
6 Port fo r test lead
7 Portfor pressure-sensor lead
Saab9
of
l
s-
Test prompts
Measured values and error codes, with over
view
of test
items
Valve
and
ABS-version monitor
BS system tester
59 3
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1d
e
,
1-
. .
This part
of
the display shows instantaneous val
ues for wheel speed, wheel sensor signal
amp li tude, sensor-wheel eccen tric it y - and
which wheel the values refer to.
A check is a lso made of the relays, and
of
ac
cumulator pressure ifthe pressure sensor is con
nected. Error codes are displayed at the end
of
the run.
The valves operating during the test are indi
cated
as
is the ABS-system version selected.
, Displaysdriving instructions
forthe
operatordur
, ing testing.
(Details
of
individual prompts are given
on
page
590 5.
,
.
t
} .
l
r
{ .
j
t
f
0
j
Saab9
590-4
ASS-system tester
ITimI
IGNITION
I
IGNITION
OFF
DRIVE)20 Km/h APPLY BRAKE
I STOP CAR
STRIKE RElEASE BRAKE I
SYSTEM OK
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Saab900
c
rq
t
lo
a RR
Ilm/h
~ r n r n t m ~ o o ABS-TYPE
v { {
h h R R
1 2 3 4
t
START
TEST
Function
(1) (1)
0.
01
NEXT
> t::
ERROR
E < l
u
CODE
4>
Function
Al:>
ABS-System
tester 1
89965 4
Brakes
V
-
n
There are three buttons of the membrane-switch
type
on
the control panel:
Button A is used to start the test cycle and to run
through the error codes.
Button B is used
to selectthe
program
that
mea
sures wheel-sensorsignal strength, tests the op
eration
of
the wheel sensors and measures ac
cumulator pressure if pressure sensor con
nected) .
Button C is used to select the program that mea
sures sensor wheel eccentricity, to testthe oper
ation of the wheel sensors and to measure ac
c umul ator pr es sure ( if pr ess ur e s ensor con
nected).
Buttons Band C can be depressed simultane
ously to select the ABS-system version.
A
ASS-system tester
59 5
lmll
IGNITION ON
I
IGNITION OFf
DRIVE)20 m/h I APPlV BRAKE I STOP CAR
Dill
STRIKE
RelEASE BRAKE ISYSTEM OK
= =
=
=
PRESSURE
U
UFLBFR
O o R
RR
Note
The test prompts do not appear in the order
shown
on
the display butvarywith
th e test
being
run.
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.
m/h
~ r n r n n J I T l W [ I D
S ~ T V P E
[ ~ ~ R R 3 ~
~
Turn the ignition key
to
the drive position
The program startsthe test
u ESu
IF
brake pedal pulsates
or
pedal travel is greater
than normal: switch of f ignition within
1
sec
onds.
If the pedal nei ther pulsates nor s inks to the
floor, leave the ignition on and
wait
2 seconds
for the next prompt.
\
t
t
I
.
.
i i
lQ RUVlE > 2
km h
Drive the car at a speed greaterthan 2 km/h 13
mph)
but
less than
3
km/h 19 mph)
AIPPIL
Y IBIRAKIE
Press down hard
on
the brakepedal immediately
Take your foot off the accelerator and let the car
coast. Light braking using handbrake only is per
missible.
Foot
of f
brake. No braking permissible
Test completed:
no
fault
found.
Saab9
5 ~ ~ . 6
S ~ s y s t e m
t st
~ g l l ] ~ i j v a ~ u e s ertrtorr odes
Ihstantaneous values
for
wheel speed, wheel
sen$or signal ampli tude, sensor wheel out-of
r,ou, d.and, if the pressure sensor is connected,
hydraulic pressure in the accumulator are shown
on the display, Also shown on
the
display are the
words
ERROR
O E followed by the al
phanumeric code forthe
f ult
detected,
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Hydraulic pressure in the accumulator
f
Front Right wheel
L
Front Left wheel
R L
,
l
Rear Left wheel
Rear Right wheel
Saab
ABS system tester
59
7
. ; . _ : : . . . _
M
V
Main Valve
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fF
l
Inlet Front Left left
ront inl t
valve)
Outlet Front Left left
ront
outlet valve)
Inlet Front Right right ront inl t valve)
o
R
Outlet Front Right right
ront
outlet valve)
Inlet Rear rear
inl t
valve)
Outlet Rear rear
outl t
valve)
34
Indicates the ASS-system version selected
Saab
Althou.gh;tMe ABS-system
testeris
the
most
im
portantfault.,.diagnosis aid availabt,e_forthe
ABS
s ys te m, a lw ay s p er fo rm t he fo llow ing_ q ui ck
chec.ksb efo_re.connecting the tester.
IBrake fhdd leveD
59 8
ABS-system tester
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Saab900
el y n fuse
p nel
1 Relay, p um p motor
2 Relay, ECU
3 Fuse,
ECU
10
A
ABS
4 Fuse,
ECU
30A
ABS
5 Fuse, p ump motor 30A Pump
r r r s p ~ t all
the
fuses in thefuse panel adjacent
to
the
ABS-system
ECU.
IFMses
The
fluid
level in the reservoir must be checked
with
the
accumulator fully charged with f luid.
Switch on the ignit ion and check the fluid level
after
the
hydraulic pump has cut out.
Top up, as necessary, with DOT 4 brake
f lu id to
bring
the
level up
to
the X mark on the side
of
the reservoir.
ASS-system
tester 59 9
8,6
0
;
0
:
85
,
I
~ e n i i l l
Check thatthe relay
for
the
ECU
and the relay for
the
pump motor have been fitted correctly.
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87a
c::::J
83 1
el y
orpu p otor
86 Voltage via fuse. 10 A BS
85 Earth via pressure switch accumulator pressure
4 bar
87 Output
to
pump and
ECU
pin 32
3 Voltage via fuse 30APump
I
87
3
I
el y or
U
3 Output to
ECU
pins 3 and 2
85
Earth
87a Earth
87 Voltage via fuse 30A
SS
86 Output
to
ECU pin 8
Saab9
\
59 1
SS system tester
Check l l electrical connections:
Pressure switch
Mastervalve
\ Fluid level indicator switch o reservoir
Electric motor for pump
Connector o valve block
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Also check t t the sensor lead connectors
are making good contact:
Both connectors in engine compartment
J
Both connectors under rear seat
IEali hlBlrog f l o i l ~ s
Check all earthing points:
wheel arch
o
On bracket between hydraulic unit and front
assembly
~ a a b
SS system
t st
59 11
.
Secure
the
connector
by
fi1Jing
a
strap roLjr d
Switch of f
the
ignition.
2 Remove
the ECU
3 Connect
the
tester lead the>ECU
and the ABS wiring loom by means of.
the
two-way
35 pin
connector.. .
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LO
0
the
ECU and connectors.
Run
the test lead down between
the
wheel arch and Apil lar and then into
the
car
via the bottom corner of the door opening.
Connect
the
lead
to
the tester.
Saab9
59 12
SS system tester
4 Connect the powersupply lead
to
the battery
negative terminal first).
Run
the lead through the opening in the
R
A
pillar
and connect
it to
the tester.
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Note
Ensure that the connector is instal led
the
right
way round. Ifthe connector is
fitted
upside down,
the
tester wi
be seriously damaged.
Thetesterwill
nowautomatically selectABS-type
1.
Saab
: - ~ @ O i l [ l i ) < e ~ ~ O l l i ] g
[QHi teMIr rro
: ; @[f
. ; ~ I t is not necessary to connect the pressure sen
~ s o r un lessa pressure-related fault issuspected.
. . '\.
ABS-system tester 590 13
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1 Pressure sensor
2 Fitting with groove f or 0 ring
3 Washer
4 Sleeve
5 '0 ' r ing
Tightening torque:
34
46 Nm (25
34 ib1
ft)
Saab900
5 Connect the pressure sensor lead to thetes
ter.
To disconnect the pressure sensor, reverse
the
procedure for connecting it.
VI >
cJ lrmsd
ftlh jpfi'SSllIJ[fe sell1lJ fi
1 Remove the accumulator.
2 Connect hose
8996597 to
the connection
for the accumulator on the hydraulic unit.
3 Connect th e pressure sensorto the hose.
4 Connect the accumulator to the pressure
sensor.
I
l
59 14 ASS-system tester
thee
~ l i 1 1 g ~ l l
l U J ~ a f t Q r r
gas
Ifess
Connect the tester and pressure sensor as de
tailed on pages 59 11 and 590-13.
1 Set the testerso that
PR SSUR
is shown on
the display.
2 Switch on the ignit ion
and
let the pump
run
until the
SS
Anti-lock warning light goes
off.
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3 Switch off the ignition.
4
Pump
the brake pedal
and
watch the display
on
the tester.
ach
timethe pedal is dessed,
the hydraulic pressure
in
the brake system
drops.
The moment the hydraulic pressure has fal
len to the same level as the gas pressure
in
the accumulator, the value 0 will appear
on
the display.
Note the value shown
on
the display im
mediately before the 0 value appears. This
value denotes the gas pressure in the ac
cumulator bar .
The gas pressure in the accumulator should
be
between
4
and 8 bar.
Saab9
SS systemt st 59 15
e ~ e < c f r D U i 1 g
U - U t = ~ ' Y ~ < e m
W ~ W c
s
s soon as the tester is powered up, it automati
cally s e l e c t ~ B S t y p e 1. This isthe system ver
. s ian wi th a 94-tooth sensor wheel, f it ted to al l
. 989 and earlier models.
The letter t (teeth) is shown on the display
followed
by
thefigure 94 , indicating the number
of teeth
on
the sensor wheel. (Note that
sO me
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(
(
(
Y Vf
SI ART
TESI
=t_tnl
89/illS51.
erak
BS type
1 Sensor wheel with 94 teeth
2 Sensor wheel with 46 teeth
3 Not used
4 Not used
A couple of seconds after the
BS
version has
been selected, the tes ter wi ll au tomat ical ly
switch to Monitor Mode (manual test cycle).
Selection
of
an alternative ABS-system version
must be madewithin four seconds
of
power
up b y
pressing the two function buttonssimultaneous
ly.
The following
BS
versions are in use:
testers will display the figure 96 .)
ABS-type 1 indicates the automaticallychosen
system.
Saab9
The tests in this mode are the same as those in
Monitor Mode, except
that
here the tester
switchesautomaticallyfrom onetest to the next.
To enter Test Mode:
o Make sure that the tester i s in the Monitor
Mode, ready to measure wheel speed this is
the status the tester enters automatical ly
af ter t he A8S-system version has been
selected)
59 16
ASS-system tester
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\
)
\
- I
====
Irno
faults have been detected, the display will
read
SYSTEM OK.
Saab9
o Drive the car at a speed above
km/h
6 mph).
Press the START
TEST
button.
TEST wi
II now start
to flash on the_.display, indicating that the Test
Mode has.beerrinitiated.
If
the tes ter does not enter the Test Mode, re
main in Monitor Mode and check the wheel sen
sor signal amplitude for each wheel.
For accurate test results, the car must be driven
for at least three minutes at a speed of about
7
knn/h
42 mph). The test resultswill not beaf
fecter by the car s topp ing and start ing in re
sponse to traffic conditions. The test cycle for
eachwhe_el takes,about two seconds; testing the
accumwlatorpressuretakes a
bi t
longer approx.
four seconds) because the relays are also
checked.
The tes ter wi ll bleep each time a fault is de
tected.
Rectify any faults by locking up the errorcode
in
the fault-diagnosis routine.
Testing will continue until the tester is switched
of f orthe START TEST button is pressed for about
three seconds.
To
read thetest results:
1 Stop the car.
11
not switch
of f
the ignition.
2 Wait until the display indicates FR, FL,
RL
or
RR and press the START
TEST
button.
If any faults have been detected,
ERROR
wi II ap-
pear on the display followed by a figure indicat-
ingthe number
of faults
found.
To read the error codes, press the NEXT ERROR
ABS system tester
59 17
.
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O E button and the error codes will be dis-
played. Pressthe button again to read each suc-
cessive error code.
If several error codes are displayed togetherthey
must be
investigated and rectified
in
the follow-
ing order:
E002
EE24
EOOl
E033
E422
EE25
E009 E034
E523
EOll
E010
E035
E624
E008
E015 E132
E725
E320
E016
PRES
EE22
E014
E017
EE23
E032
E018
To return to MonitorMode, press one
ofthe
func-
tion
buttons.
Saab 9()O
,.
59 18
ASS-system teste r
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. .J
r - - - \
Saab9
The t est er wi ll bleep each t im e a fault i s de
tected.
Make sure that the te ster is in Monitor Mode
entered automatically
by
the tes ter a fte r the
ASS-system version has been selected)
The car must be
at
a standstill with the engine
running.
Press one
of
the
FUNCTION
buttons
to
enter the
Valve Test Mode. The SS Anti-lock) warning
light on the ins trumen t p ane l wil l c ome on and
remain on throughout the test sequence.)
Pressithe
ST RT TEST
button.
TEST
will now flash
on the display, indicatingthat the
test
sequence
has been initiated.
To enterthe Valve Test Mode:
ABS-:system tester 59 19
Note
When the rear inlet valve IR is to be tested ,
choose a p lace to stop the car
Where
it
can re-
main parked whi lst the remain ing valves are
IFL
Inlet Front Left
IFR Inlet Front Right
IR
Inlet Rear
: The valves are tested in the fol lowing order:
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This sequence will be repeated automatically to
test
the
other inlet valves.
Press down hard on
the brake pedal as soon as
the text appears. The tester wil l measure the
wheel retardation as the car s lows from 15 to
13
km/h.
l fPl
BR KlE
As. soon as
the
car has stopped, re lease the
brake pedal. Do nottouchthe brake pedal again.
When
thetest
sequence for the
inlet
valves has
been completed, the tester wil l automat ical ly
continuethe nextsequence, i.e. testing the out-
let
valves and main valve.
Saab
Foot
off
the accelerator and
letthe
car coast. Do
not touch the brake pedal: use
the
handbrake
if
you need to slow the car down. Depress the
clut.ch pedal manuals only and be ready to
brake when APPLY BRAKE appears on
the
display
after
the
road speed has dropped to about
18
km/h or
11
mph .
Drive
the
car
at
a speed above
2
km/h 13 mph
but not
over
3
km/h 19 mph .
During
this
test, the fol lowing prompts wil l ap-
pear on
the
display in the order shown:
STOlP CAR
amd RIELEASE
BRAKE
tested.
O
ut l
et
Re
ar
r
ea
r o
u
tl e
t v
alv
e
O
u
tle
t F
ro
nt
R i
gh
t
O
u
tle
t F
ro
nt
Le
ft
M
a
in
va
lve
OR
O
F
R
O
FL
N ote
D
ur
in
g t
e s
ti n
g
of
th
e
m a
in
v
alv
e M
V
th
e
br
ak
e
p
ed
al
w
ill
pu
ls
at e
s
tro
va
Rv
es 3
l
\ld
m
a
in
va
h
le
T
he
o
u tl
e t
va
lve
s
an
d m
a
in
va
lve
a
re
te
st e
d in
th
e
fo l
lo w
in
g
or
de
r:
5
9
2
A
S
S
-s
y
st
em
te
s
te
r
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S
aa
b
T
he
se
q
ue
nc
e w
il
l b
e
re
pe
ate
d
a
ut o
m
a t
ic a
lly
t
o
test th e
ot h
er
o
u tl
e t
va
lv
es
an
d
th
e m
a
in
va
lve
.
Q
S
tR
O
K
E
->
a
Jtril
d
I
ru
ue
O
ff
Bo
th
fla
sh
in
g
T
he
pe
da
l
sh
ou
ld
pu
ls
ate
o
r t
he
re
s
ho
uld
be
e
x
c
es
si
ve
p
ed
al
tra
v
el
wh
e
n
th e
p
ed
a
l i
s d
e
pr e
s
se
d. If
so
, s
w
itc
h o
ff
th
e
ig n
it
io n
w
ith
in
10
se
c
onds
to
send
an
acknowl edg em ent to th e te ste r.
If
th
e
pe
da
l d
oe
s
no
t
re s
po
n
d a
s
de
sc
rib
e
d, d
o
n
o t
sw
itc
h o
ff
t
he
i
gn
it io
n
. W
a
it
ab
ou
t 2
0
s
ec
o
nd
s f
ort
he
n
ex
t p
ro
m
pt R
E
LE
AS
E
B
RA
KE
to
ap
pe
a
r o
n th
e
d
isp
la
y.
If
n
o
fa
u lt
s
ha
ve
be
e
n d
e
te c
te
d,
th
e
dis
pl
ay
w
ill
r
ea
d SY
ST
EM
O
K.
Pr
es
s
do
wn
h
ard
on
th
e
b
ra
ke
p
ed
al
a
s s
oo
n
as
t
he
te
x t
ap
pe
ar
s.
S
wi
tch
o
n t
he
ig
ni
tio
n
tu
rn
ke
y t
o d
ri
ve
po
si
ti o
n
R
El
EA
S
E
I8
lR
AK
IE
B
ef o
re
s
ta r
tin
g
th
e t
es
t:
o
Th
e c
ar
m
us
t be
at
a s
ta
nd
st
il l
wi
th
th
e e
n
gi n
e
sw
itc
he
d
of
f.
D
u
ri n
g th
is
te s
t,
th
e
fo
ll o
w i
n g
p
ro
m p
ts
w
il l
ap
p
ea
r
on
th
e
dis
pl
ay
in
th
e
or
de
r s
ho
wn
:
ng
ly
.
Do
n o
t t
ou
ch
th
l;Y
b
ra
ke
p
ed
al
. B
ra
ki
ng
is
t
a
llo
w
ed
.
A
ft
er
a
bo
ut
fiv
e
se
co
n
ds
, t
he
p
um
p
w
il l
h
av
e
. r
ai s
ed
t
h e
p
re
ss
ur e
i
n
th
e
ac
cu
m
ul a
to
r t
o
ap
pro
x.
18
0
b
ar
2
61
0
p
si
a
nd
R
EL
EA
SE
B
RA
K
E
w i
ll d
is
ap
pe
ar
fr
om
th
e
di
sp
la
y.
A I
?P
lV
[sl
R
l}{l
ASS-system tester 5 90-21
If anyfaults have been detected
ERROR
will ap
pear on the display followed by a figure indicat
ing the number
of
faults found.
To
read the error codes press the NEXT ERROR
O E bu tto n and t he error codes wil l be di s
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E002
EE24
EOOl E033
E422
EE25
E009 E034
E523 EOll E010 E035
E624
E008
E015 E132
E725
E320 E016 PRES
EE22
E014 E017
EE23
E032 E018
Saab
To return to Monitor Mode press one
ofthe
func
tion
buttons.
If several error codes are displayed togetherthey
must
be investigated and rectified in the follow
ing order:
played. Press the button again to read each suc
cessive error code.
59 22
ASS-system
tester
After
the
t es te r has been powered up and the
ABS-sY tem vers ion selected, the tester wil l
u t o r r i ~ i l l y
enter the Monitor Mode.
The following tests can now
performed:
Wheel speed
Wheel sensor signal amplitude signal
strength)
Sensor wheel eccentricity out-of-round)
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Wheel-sensor circuit continuity and function
check
Accumulator pressure
i f
pressure sensor con
nected)
The test er will bleep each time a fault is de
tected.
Saab9
SS system tester
59 23
This test must be carried out with the car being
driven
at
a steady speed.
Km/h will appear
on
the display together with a
number, indicating the speed of the wheel in
km/h.
FR on the display indicates that the front right
. wheel is being tested. .
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SfAR
T f
XT
RROR
CODE
= I_ ell L
t ~ 9
5
nk s
Some of the valve segments may flash during
this
test ; this is qui te normal and can be dis-
regarded.
Saab
If the pressure sensor is connected, PRESSURE
will appear
on
the display together with a value
indicating the accumulator pressure in bar this
is the working pressure of the brake system .
To
test the speed of the other wheels, press the
top FUN TION button. The wheels wil l now
be
tested in an anticlockwise sequence, as shown.
The
test can also
be
performed in a clockwise
sequence - press the bottom
FUN TION
button.
The values should
be
rough ly the same for al l
four wheels.
ST RT
TEST
=laml l I r
9g6S1
W h e e ~ L s e l l l s o l i sogli1lai a m l J l ~ D t l l O d e
Th'fs test must be carried out with the car being
di: i,v.en at a steady speed.
Press; the top
FUNCTION
button for about three
seconds.
The
tester will nowmeasure the signal
ampPitude from the wheel sensors.
590 24
ASS-system tester
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\ R SSUR
B
h
NEXT
ERROR
CODE
ST RT
TEST
=I.m In l
/19
OG 51
en