Filling/Bleeding The Clutch System: Filling/Bleeding

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 litres = 000.043.203.67 

1. Remove cover over the brake fluid reservoir. Fill reservoir to its top edge with new brake fluid. Connect the bleeding device to the reservoir. → see figure 

   Do not switch on the bleeding device yet! 

   Fig 1: Filling Brake Fluid On Clutch System Reservoir

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.
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 -1-  at the clutch slave cylinder -2-  and close it off immediately using bleeding tool 9781 -5-  .
   1. 3.1 Release return line -1-  at the clutch slave cylinder -2-  (-arrows-  ) and pull it off the bleeder valve -3-  at the same time.
      Fig 2: Releasing And Removing Return Line

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   2. 3.2 Then, insert bleeding tool 9781 -5-  , set to Closed position (knurled screw -6-  turned clockwise as far as it will go), into the return line -1-  .
      Fig 3: Identifying Bleeding Tool 9781

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

4. Switch on the bleeding device and set an overpressure of approx. 1.3 bar.
   Fig 4: Filling Brake Fluid On Clutch System Reservoir

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.
5. Connect a collecting bottle -7-  with a transparent hose to the bleeder valve -3-  .

   Open the bleeder valve -3-  on the clutch slave cylinder -2-  by 1 to 2 turns.

   Fig 5: Connecting Collecting Bottle To Bleeder Valve

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6. Move 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, activate complete pedal travel with your hand very slowly for a further 60 seconds. After about 10 to 15 pedal strokes, leave the pedal in its normal position. Once this filling period has elapsed, check that no more bubbles appear at the bleeder valve (use a collecting bottle with a transparent hose). Then close the bleeder valve (tightening torque = 5 + 1 Nm (3.5 + 0.5 ftlb.).
9. Fill/bleed the return line -1-  using the bleeding tool 9781 -5-  .
   Fig 6: Collecting Bottle Hose On Return Line

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   1. 9.1. Connect collecting bottle (with a transparent hose) -7-  to the return line -1-  or to the fitted bleeding tool 9781 -5-  .

      Open bleeder valve (knurled screw) -6-  on special tool -5-  . Let brake fluid flow through until no more air bubbles appear. Then close the knurled screw -6-  .

   2. 9.2. After bleeding the return line, switch off the bleeding device. 
10. With the bleeding device switched off,  fit the clutch return line -1-  on the bleeder valve -3-  (of the clutch slave cylinder -2-  ).
    1. 10.1. Remove special tool 9781 -5-  from the return line -1-  .
       Fig 7: Return Line With Special Tool 9781

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    2. 10.2. Then, fit the return line -1-  on the bleeder valve -3-  of the clutch slave cylinder -2-  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 seated correctly!

       Fig 8: Fitting Return Line

       Courtesy of PORSCHE CARS NORTH AMERICA, INC.
11. Close off the bleeding device, which is now switched off. Check the brake fluid level. It should not be above the MAX marking on the brake fluid reservoir.
    Fig 9: Check Brake Fluid Level

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12. Activate the clutch pedal slowly, five times.
13. Fit the cover over the brake fluid reservoir.
14. Fit cover for rear underbody. → 519419 REMOVING AND INSTALLING COVER FOR REAR UNDERBODY .