| General Procedures Special Tool(s) | | Vacuum and pressure hand pump 416-001D (23-036A) | General Equipment Brake fluid collector Transparent hose Materials Name Specification Brake fluid (Dot 4) SAM-6C9103-A Vehicles built up to 08/1999 WARNING:Brake fluid contains polyglycol ether and polyglycol. Prevent eye contact. Wash your hands thoroughly after working with brake fluid. If brake fluid gets into the eyes, wash the eyes with cold running water for 15 minutes. If the irritation persists, call a doctor. If brake fluid is swallowed, drink water and induce vomiting. Call a doctor immediately. Failure to follow these instructions can lead to injury. CAUTION:If any brake fluid gets on the paintwork wash it off immediately with water. NOTE:Absolute cleanliness must be observed when topping up with brake fluid. NOTE:Do not re-use brake fluid. | | -
NOTE:Continually check the brake fluid level while bleeding the system and top it up as necessary. - Slowly depress the clutch pedal fully and fix it there.
- Open the bleed nipple. As the clutch engages the brake fluid is driven out of the clutch slave cylinder through the bleed hose.
- Free the clutch pedal and pull it right up.
- Repeat the bleeding process until the brake fluid which flows into the collector is clear and free of bubbles.
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Bleed the clutch system. - Tighten the bleed nipple.
- Pull off the hose and put on the protective cap.
- Operate the clutch pedal ten times, if necessary pull the clutch pedal back to its normal rest position by hand.
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NOTE:Absolute cleanliness must be observed when topping up with brake fluid. Check the brake fluid level. - The brake fluid level must be between the MIN and MAX marks.
| Vehicles built from 08/1999 | | -
NOTE:If proprietary brake bleeding equipment is available, this can be used to bleed the clutch system. General note: - The clutch operation system is self-ventilating. The components are arranged in such a way that small amounts of air trapped in the system are removed automatically.
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Remove the brake fluid from the brake fluid reservoir under suction, until the level is at the MIN mark. | | | -
Put about 100 ml of brake fluid into the reservoir of Special Tool 416-D001. | | | -
NOTE:The reservoir of the special tool must be below the bleed nipple and the hose connection of the rising tube must be installed pointing towards the bleed nipple. Install the special tool, open the bleed nipple and use the special tool to pump about 80 ml of brake fluid into the clutch system. - Tighten the bleed nipple to 10 Nm.
- Bleed the system automatically by operating the clutch pedal several times (max. 4 - 5 times), using the full clutch pedal travel.
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NOTE:Absolute cleanliness must be observed when topping up with brake fluid. Check the brake fluid level. - The brake fluid level must be between the MIN and MAX marks. If the level drops below the MIN mark the brake warning light comes on.
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NOTE:Carefully engage reverse gear. Check that the clutch operates correctly. - Start the engine and carefully engage reverse gear about 2 seconds after depressing the clutch pedal. If in doing so the gear engagement is particularly noisy, bleed the system automatically by operating the clutch several times (max. 4 - 5 times), using the full clutch pedal travel.
- After waiting about 30 seconds, check the operation of the clutch again. If the gear shift is still too noisy, repeat the previous job steps.
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