Bleeding the iB5 clutch system

Special tool

Vacuum/Pressure Hand Pump 416-D001 (23-036A)

Name	Specification
Brake Fluid Super DOT 4	ESD-M6C57-A

WARNING: Do not allow brake fluid to come into contact with skin or eyes. If brake fluid comes into contact with the skin or eyes, immediately flush the affected area with water. Failure to follow these instructions may result in injury.

CAUTION: If brake fluid comes into contact with the paintwork, immediately wash the affected area with water.

NOTE: Absolute cleanliness must be observed when adding brake fluid.

NOTE: Do not reuse brake fluid.

NOTE: When equipped with the appropriate brake bleeder equipment, it can be used to bleed the clutch hydraulics.

1. General notes:

• The hydraulic clutch is a self-ventilated system. The elements are arranged in such a way that the smallest amount of air that enters the system is removed automatically.

2. Remove the air filter.

• 1. Disconnect the inlet hose.
• 2. Disconnect the plug connector of the mass air flow sensor (MAF).
• 3. Disconnect the crankcase ventilation hose.

3. Remove the air intake pipe.




4. Suck out the brake fluid from the brake fluid reservoir by suction until the level drops to the MIN·mark.



5. Add approximately 100 ml of Super DOT 4 brake fluid to the reservoir of the special tool 416-D001.

6.

NOTE: The special tool reservoir must be below the bleed nipple and the riser hose connection must face towards the bleed nipple.

Install the special tool, open the bleed nipple and use the special tool to fill approximately 80 ml of Super DOT 4 brake fluid into the clutch system.

• Tighten the bleed nipple to 10 Nm.
• Disconnect the special tool.
• To remove any small amount of air remaining in the system, operate the clutch pedal several times (4 - 5 times max), depressing the pedal for the full length of its travel.

7. Install the intake piping.




8. Install the air filter.

• 1. Connect the inlet hose.
• 2. Connect the plug connector of the mass air flow sensor (MAF).
• 3. Connect the PCV hose.

9.

NOTE: Absolute cleanliness must be observed when adding brake fluid.

Check the brake fluid level.

• The brake fluid level must be between the MIN and MAX marks. If the fluid level falls below the MIN·mark, the brake warning light comes on.
• Fill the tank if necessary. The reservoir must be filled with Super DOT 4 brake fluid.

10.

NOTE: Carefully engage reverse gear.

Check the correct operation of the clutch.

• Start the engine, depress the clutch pedal and wait approximately 2 seconds before engaging the reverse gear. If during this operation the gear engagement is accompanied by a particularly loud noise, remove the small amount of air remaining in the system by depressing the clutch pedal several times (4 - 5 times max), depressing the pedal for the full length of its travel.
• After a pause of approximately 30 seconds, check the operation of the clutch again. If the gear engagement is still accompanied by excessively loud noise, repeat the above operations.