Filling/Bleeding The Clutch System

Information 

In general, a minimum filling time of 90 seconds must be observed.

Use only new Super DOT 4 class brake fluid. This brake fluid is available under the following part numbers:

• Container quantity 1 liter = 000.043.203.66 
• Container quantity 30 liters = 000.043.203.67 

1. Remove the cover over the brake fluid reservoir. Fill new brake fluid up to the upper edge of the reservoir. Connect the bleeding device to the reservoir.

   Do not switch on the bleeding device yet! 

   Fig 1: Identifying Brake Fluid Reservoir Connection

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2. Remove cover for rear underbody (to gain access to the bleeder valve and return line).

   → 519419 REMOVING AND INSTALLING COVER FOR REAR UNDERBODY .

3. Remove return line at the clutch slave cylinder and close it off immediately using bleeding tool 9781  .
   1. 3.1. Release return line at the clutch slave cylinder by pressing the clips -A-  together and pull it off the bleeder valve -B-  at the same time.
      Fig 2: Identifying Return Line

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   2. 3.2. Insert bleeding tool 9781 -2-  into the return line -1-  . The bleeding tool must be closed (knurled screw turned clockwise as far as it will go).

      Brake fluid will emerge for a short time until the return line is closed off (soak up brake fluid using a lint-free cloth).

      Fig 3: Inserting Bleeding Tool Into Return Line

      Courtesy of PORSCHE CARS NORTH AMERICA, INC.
4. Switch on the bleeding device and set an overpressure of approx. 1.3 bar (17 psi).
5. At the bleeder valve -1-  , connect the collecting bottle -2-  with a transparent hose.
   Fig 4: Connecting Collecting Bottle

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   1. 5.1. Open the bleeder valve on the clutch slave cylinder by 1 to 2 turns.
6. Move the pedal extremely slowly to the "Pedal fully depressed" position. When doing so, guide the pedal by hand so that it does not move forward abruptly.
7. Allow the brake fluid to rinse through for 30 seconds.
8. Afterwards, actuate the pedal fully very slowly with your hand for a further 60 seconds. After about 10 to 15 pedal strokes, leave the pedal at its normal position. Once this filling period has elapsed, check that no more bubbles appear at the bleeder valve (use a collecting bottle with transparent hose). Then close the bleeder valve (tightening torque = 5 + 1 Nm (3.5 + 0.5 ftlb.).
9. Fill/bleed the return line using the bleeding tool 9781.
   1. 9.1. Connect collecting bottle -1-  (with a transparent hose) to the return line or to the fitted bleeding tool 9781 -2-  .
      Fig 5: Connecting Collecting Bottle To Tool

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   2. 9.2. Open the bleeder valve (knurled screw) on the special tool. Let brake fluid flow through until no more air bubbles appear. Then close the knurled screw.
   3. 9.3. After bleeding the return line, switch off the bleeding device. 
10. With the bleeding device switched off,  fit the clutch return line on the bleeder valve (of the clutch slave cylinder).
11. Remove special tool 9781 from the return line.
    1. 11.1. Then, fit the return line on the bleeder valve of the clutch slave cylinder immediately (connect until it locks).

       Brake fluid will emerge for a short time (soak up brake fluid using a lint-free cloth). The emergence of brake fluid is normal and does not affect the system function. Check that the return line is fitted correctly!

       Fig 6: Fitting Return Line

       Courtesy of PORSCHE CARS NORTH AMERICA, INC.
12. Close off the bleeding device, which is now switched off. Check the brake fluid level. The level must not be above the MAX marking.
13. Press the clutch pedal five times, pressing down slowly as far as it will go and then back up.
14. Fit the cover over the brake fluid reservoir.