Bleeding The Clutch System

Information 

General information on the work procedure:

• The clutch system must always be filled/bled using a suitable bleeding device.
• The bleeder valve must be opened by at least one but no more than two turns.
• The bleeding pressure to be set on the bleeding device is approx. 1.3 bar.
• A minimum filling time of 90 seconds must be observed.
• Once the filling or bleeding process has started, the clutch pedal must be moved (extremely slowly) into the "Pedal fully depressed" position.
• As there is no system pressure, servo kinematic effects will cause the clutch pedal to move forward abruptly. To prevent damage, the pedal must be guided by hand.

1. Change brake fluid in the brake fluid reservoir -1-  .
   1. 1.1 Open cap on brake fluid reservoir -1-  .
   2. 1.2 Extract old brake fluid in the brake fluid reservoir -1-  completely using suitable aids.
   3. 1.3 Fill the brake fluid reservoir with new brake fluid -1-  up to the Maximum marking (max) -arrow B-  .
   4. 1.4 Connect bleeding device to the brake fluid reservoir -1-  .

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   Min/Max markings on brake fluid reservoir

2. Only if you have not already done so when removing/installing the clutch slave cylinder:

   > 9781 - Bleeding tool  must be inserted into the return line -1-  on the clutch slave cylinder.

   1. 2.1 >9781 - Bleeding tool  must be ready and closed  (knurled screw turned clockwise as far as it will go).
   2. 2.2 Release quick connector on return line -2-  .
   3. 2.3 Pull return line -1-  off the bleeder valve and insert >9781 - bleeding tool  into the return line -1-  immediately.
   4. 2.4 Catch escaping brake fluid using suitable aids.

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   Return line on clutch slave cylinder

3. Prepare for bleeding.
   1. 3.1 At the bleeder valve -1-  on the clutch slave cylinder -2-  , connect a suitable collecting bottle with transparent hose -3-  .
   2. 3.2 Switch on the bleeding device and set an overpressure of approx. 1.3 bar  .
   3. 3.3 Open the bleeder valve -1-  at the clutch slave cylinder -2-  by 1 to 2 turns.

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   Collecting bottle on clutch slave cylinder

   Information 

   You will need a second mechanic to help you with this step.

4. Bleed the clutch system.
   1. 4.1 Move the clutch pedal extremely slowly to the Pedal fully depressed  position. Guide the pedal with your hand to prevent it from moving forward in an uncontrolled manner.
   2. 4.2 Let brake fluid run through the clutch system for about 30 seconds.
   3. 4.3 Continue to bleed the system for 60 seconds and slowly pump the pedal fully with your hand 10 to 15 times.
   4. 4.4 Check the brake fluid that comes out at the bleeder valve -1-  for air bubbles. If necessary, continue bleeding until there are no more air bubbles.
   5. 4.5 As soon as there are no bubbles in the escaping brake fluid:

      Close and tighten the bleeder valve -1-  .

      > Tightening torque 5 Nm (3.7 ftlb.) 

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   Collecting bottle on clutch slave cylinder

5. Bleed the return line -1-  .
   1. 5.1 >9781 - Bleeding tool-2-  with collecting bottle -3-  must be connected to the return line.
   2. 5.2 Open the knurled screw on the >9781 - bleeding tool-2-  and bleed the system until there are no bubbles in the escaping brake fluid.
   3. 5.3 Close the knurled screw and switch off the bleeding device.

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   Collecting bottle on return line

   Information 

   Brake fluid will leak out for a short time after removing the >9781 - bleeding tool  .

   • This emergence of brake fluid is normal and does not affect the system function.
   • Catch escaping brake fluid using suitable aids.
6. Complete the clutch system.
   1. 6.1 Release quick connector on the return line -1-  .
   2. 6.2 >9781 - Bleeding tool-2-  with collecting bottle -3-  must be disconnected from the return line -1-  . Then, connect the return line -1-  to the bleeder valve on the clutch slave cylinder immediately and lock it.

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   Collecting bottle on return line

7. Remove bleeding device.

   Information 

   The brake fluid level must be between the Min  and Max  markings.

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   Min/Max markings on brake fluid reservoir

   arrow A	Minimum marking (Min)
   arrow B	Maximum marking (Max)

8. Check brake fluid level in the brake fluid reservoir and correct it if necessary.
9. Slowly actuate the clutch pedal fully five times.
10. Check that the clutch is working correctly. If the clutch does not separate correctly, the bleeding process must be repeated.